Systems and methods for solar power plant assembly

ABSTRACT

In an aspect, the present disclosure describes a method comprising using at least one robot to fully autonomously position and assemble at least one solar module and its supporting structure at a sensed geolocation without aid from a user.

CROSS-REFERENCE

This application is a continuation of International Patent ApplicationNo. PCT/US22/18368, filed on Mar. 1, 2022, claims the benefit of U.S.Provisional Application No. 63/155,193, filed Mar. 1, 2021, and U.S.Provisional Application No. 63/308,045, filed Feb. 8, 2022, each ofwhich is incorporated herein by reference in its entirety for allpurposes.

BACKGROUND

With the recognition of the harmful effects of global warming, thegeneration of usable power from solar energy is gaining increasedacceptance. Large areas of vacant land can offer an attractive locationfor the deployment of solar panels. However, such open area solarinstallations may be accompanied by significant effort in securing thesolar panels to the ground in such a way that the solar panels areresistant to external loading forces such as wind. The creation ofseparate beam and post structures to accomplish this goal can also addsignificant costs to the installation of solar panels.

SUMMARY

The present disclosure provides systems and methods for autonomousinstallation of an array of solar modules on various terrains. Someaspects of the present disclosure describe methods and systems forplanning and executing an installation of an array of solar modules overa given terrain. In some cases, terrain data from various sources (e.g.,GPS, geological survey data, cameras, etc.) may be utilized in acomputer algorithm to prepare a blueprint or instructions for deployingsolar modules on a given terrain. In some cases, one or more autonomousmachines may be used and coordinated to execute various tasks to installarrays of solar modules over a given landscape. Some aspects of thepresent disclosure provide systems and methods that can be suitable forinstalling an array of solar modules on terrains of various topologiesand compositional properties or characteristics in an efficient manner.

Some aspects of the present disclosure describe various shapes and formsof structural supports, solar modules, and coupling mechanisms that maybe formed to connect various components in a solar array. In some cases,the structural supports and the solar modules may be coupled usingmechanisms that can be formed quickly while providing stable links. Someaspects of the present disclosure provide devices and methods forcreating and deploying such coupling mechanisms so that an array ofsolar modules may be installed efficiently and rapidly without the needfor additional tools or fasteners.

In one aspect, the present disclosure describes a method comprisingusing at least one robot to fully autonomously position and assemble atleast one solar module and its supporting structure at a sensedgeolocation without aid from a user. In some embodiments, the methodfurther comprises using the at least one robot to fully autonomouslyposition and assemble the at least one solar module and its supportingstructure in two or more different directions. In some embodiments, themethod further comprises using the at least one robot to fullyautonomously position and assemble a plurality of solar modules andassociated supporting structures to construct a solar module array. Insome embodiments, the plurality of solar modules and the associatedsupporting structures comprise the at least one solar module and itssupporting structure.

In some embodiments, the solar module array is constructed on asubstantially flat terrain. In some embodiments, the solar module arrayis constructed on a substantially non-flat terrain.

In some embodiments, the solar module array is a complete wired array.In some embodiments, the solar module is a dual-tilt array. In someembodiments, the solar module array can be a single tilt array capableof or configurable for 0 degrees to 90 degrees of tilt.

In some aspects, the present disclosure describes a method comprisingproviding one or more mobile platforms that are configured to carry aplurality of posts and a plurality of solar modules. In someembodiments, the one or more mobile platforms are equipped with one ormore sensors comprising a geolocation sensor. In some embodiments, themethod further comprises using at least in part the one or more sensorsto autonomously move the one or more mobile platforms. In someembodiments, the method further comprises using at least in part the oneor more sensors to autonomously position and assemble the plurality ofposts and the plurality of solar modules over a terrain to construct anarray of solar modules. In some embodiments, the one or more sensorsfurther comprise an image sensor.

In some embodiments, the one or more mobile platforms comprises a firstplatform for positioning and installing the plurality of posts onto theterrain. In some embodiments, the one or more mobile platforms comprisesa second platform for positioning and assembling the plurality of solarmodules onto the plurality of posts. In some embodiments, the firstplatform is separate from the second platform. In some embodiments, thefirst platform and the second platform are integrated into a singleplatform.

In some embodiments, the plurality of posts are positioned and installedby the first platform at a predefined configuration onto the terrain. Insome embodiments, the plurality of solar modules are pre-stacked on thesecond platform. In some embodiments, the second platform comprises amechanism for extracting a select solar module from the stack andassembling the select solar module onto a select set of posts that havebeen installed on the terrain.

In some embodiments, the method further comprises using a testing toollocated on the one or more mobile platforms to perform pull strength andassembly tests on one or more of the plurality of installed posts.

In some embodiments, the method further comprises using the one or moresensors to locate and move an installer load head on the one or moremobile platforms relative to the array of solar modules as the array isbeing constructed.

In some embodiments, the method further comprises using a tool (e.g., anintegrated forming tool or an integrated clinching tool) on theinstaller load head to create a plurality of post-clip interfacesbetween a plurality of clips and the plurality of posts. In someembodiments, the tool may comprise any type of tool that is capable offorming, shaping, or otherwise manipulating a material (e.g., to createone or more post-clip interfaces). In some embodiments, the plurality ofclips are pre-attached on the plurality of solar modules. In someembodiments, the method further comprises forming a plurality ofclip-module interfaces, wherein the plurality of clip-module interfacescomprises a plurality of clinched joints.

In some embodiments, the one or more mobile platforms comprise one ormore electric vehicles. In some embodiments, the method furthercomprises providing one or more electric charging stations distributedacross the terrain for enabling charging of the one or more electricvehicles. In some embodiments, the one or more electric chargingstations are mobile or stationary.

In some aspects, the present disclosure describes a method comprisingproviding a plurality of posts and a plurality of solar modules. In someembodiments, the plurality of solar modules comprise a plurality ofclips pre-attached thereon.

In some embodiments, the method further comprises forming a plurality ofpost-clip interfaces between a plurality of clips and the plurality ofposts to construct an array of solar modules over a terrain withoutrequiring one or more premade holes/features for one or more fasteners.In some embodiments, the plurality of post-clip interfaces havetolerances that enable the array to contour to the terrain, therebyeliminating a need for grading of the terrain. In some embodiments, theplurality of post-clip interfaces comprise a plurality of clinchedjoints. In some embodiments, the plurality of clinched joints are formedby a dimpling process. In some embodiments, each of the plurality ofposts comprises one or more tabs. In some embodiments, the dimplingprocess comprises joining the one or more tabs to a corresponding clipto form the plurality of clinched joints. In some embodiments, theplurality of post-clip interfaces are formed at one or more corners ofthe plurality of solar modules. In some embodiments, the plurality ofpost-clip interfaces are formed at all corners of the plurality of solarmodules. In some embodiments, the plurality of post-clip interfaces areformed at opposite corners of the plurality of solar modules. In someembodiments, the plurality of post-clip interfaces are formed at one ormore lateral sides of the plurality of solar modules. In someembodiments, the plurality of post-clip interfaces are formed at alllateral sides of the plurality of solar modules. In some embodiments,the plurality of post-clip interfaces are formed at opposite lateralsides of the plurality of solar modules. In some embodiments, theplurality of post-clip interfaces are formed by using a clinching toolthat is located on a post installer load head. In some embodiments, thepost installer load head is located on one or more mobile platforms thatare configured to carry the plurality of posts and the plurality ofsolar modules.

In some embodiments, the method further comprises using the one or moremobile platforms to autonomously position and assemble the plurality ofposts and the plurality of solar modules over the terrain to constructthe array of solar modules.

In some embodiments, the method further comprises assessing a structuralintegrity of the post-clip interfaces using at least one of a measuredforce or a deflection during and/or after installation of the solarmodules onto the posts.

In some embodiments, the method further comprises obtaining images ofthe plurality of post-clip interfaces during or after the interfaceshave been formed.

In some embodiments, the method further comprises determining astructural integrity of each of the plurality of post-clip interfacesbased at least on one or more of the images.

In some embodiments, the plurality of post-clip interfaces are formedwithout requiring the one or more fasteners.

In some embodiments, the plurality of post-clip interfaces are formed bylocating the one or more fasteners in position relative to each clip anda corresponding tab on each post, and piercing the one or more fastenersthrough the tab to fasten the tab onto the clip, or piercing the one ormore fasteners through the clip to fasten the clip onto the tab.

In some embodiments, the method further comprises using a movable toolto form a plurality of holes in-situ on at least the clips on the solarmodules and/or tabs on the posts. In some embodiments, the methodfurther comprises using the movable tool or another tool to install theone or more fasteners through the plurality of holes formed in-situ onthe clips and/or tabs. In some embodiments, the method further comprisesadding the one or more fasteners to the post-clip interfaces after orduring the dimpling process.

In some aspects, the present disclosure describes a method comprisingusing an algorithm to identify a location suitable for autonomouspositioning and assembly of at least one solar module. In someembodiments, the method does not require aid or involvement from a userin the autonomous positioning and assembly of the at least one solarmodule.

In some embodiments, the algorithm is a machine learning (ML) algorithm.In some embodiments, the algorithm identifies the location based atleast on an analysis of terrain data. In some embodiments, the terraindata is obtained using at least one of aerial imaging or Globalnavigation satellite systems (GNSS).

In some embodiments, the method further comprises creating a set ofexecutable instructions in a digital medium for an autonomous system toautonomously position and assemble the at least one solar module toconstruct a solar module array.

In some embodiments, the autonomous system comprises a plurality offield machines that are in operative communication via a network. Insome embodiments, the plurality of field machines comprise robots.

In some aspects, the present disclosure describes an apparatus that isconfigured to carry a plurality of posts over a terrain. In someembodiments, the apparatus may be further configured to autonomouslyposition a select post from the plurality of posts at a predeterminedlocation on the terrain. In some embodiments, the apparatus may befurther configured to autonomously install the select post at thepredetermined location, wherein the select post and the plurality ofposts are useable to support a plurality of solar modules.

In some embodiments, the apparatus may be further configured to performa force test after the select post has been installed at thepredetermined location. In some embodiments, the force test comprisesapplying a pull force on the select post in at least one of a lateraldirection or a vertical direction.

In some embodiments, the select post is installed at the predeterminedlocation by using a load driving mechanism to drive the select post intothe ground at the predetermined location. In some embodiments, the loaddriving mechanism comprises or is coupled to a hammer. In someembodiments, the load driving mechanism is mounted to and movable alonga plurality of rails in a vertical direction. In some embodiments, theload driving mechanism is configured to slide along the plurality ofrails via bearings. In some embodiments, the load driving mechanismcomprises a retention mechanism that prevents the select post fromdisplacing or decoupling from the load driving mechanism as the selectpost is being installed into the ground. In some embodiments, theretention mechanism comprises one or more shear features. In someembodiments, the load driving mechanism comprises a driving bit havingone or more shear features. In some embodiments, the one or more shearfeatures are configured to dually function as retention features. Insome embodiments, the load driving mechanism is configured having adriving force length that is less than a full longitudinal length of theselect post.

In some aspects, the present disclosure describes an apparatus that isconfigured to carry a plurality of solar modules over a terrain. In someembodiments, the apparatus may be further configured to autonomouslyposition a select solar module from the plurality of solar modules overa set of posts installed on the terrain. In some embodiments, theapparatus may be further configured to autonomously assemble the selectsolar module to the set of posts without requiring or using fasteners.

In some embodiments, the apparatus can be further configured toautonomously assemble the select solar module to the set of posts byforming a plurality of post-clip interfaces. In some embodiments, theplurality of post-clip interfaces comprise a plurality of clinchedjoints. In some embodiments, the select solar module is pre-attachedwith a clip at one or more corners or sides of the select solar module,and each post in the set of posts comprises a plurality of tabs. In someembodiments, the apparatus is configured to autonomously position theselect solar module over the set of posts by aligning the clip to acorresponding tab at each post. In some embodiments, the apparatus isconfigured to autonomously assemble the select solar module to the setof posts by clinching the corresponding tab to the clip at each post.

In another aspect, the present disclosure provides a ground mountsystem. The ground mount system may comprise a plurality of solarmodules that each comprise a photovoltaic material and a frame. Aplurality of clips can be connected to each of the corners of the frame.Each corner may be supported by a post implanted to a relatively shallowdepth in the ground. An upper post portion may comprise a face joined toa tab of the clip. A lower post portion may comprise a point embedded inthe ground. Increasing the frequency of vertical load-bearing postelements to occur at every intersection of the solar modules can avoidthe need for deeply excavated pillars supporting massive horizontalweight transfer components, thereby minimizing the cost of materials andsimplifying site preparation. In some embodiments, each of the pluralityof solar modules is supported above the ground exclusively by the clipand the post without requiring an additional superstructure. In someembodiments, the lower portion further comprises a sawtooth pattern. Insome embodiments, the lower portion further comprises a thread. In someembodiments, the lower portion may not or need not have any additionalfeatures other than its bends. In some embodiments, the lower portionmay comprise one or more cut-outs to make the post lighter and reducethe amount of material needed to produce a rigid and stable post. Insome embodiments, the clip includes a center tab configured to projectinto a corresponding opening in the frame. In some embodiments, theapparatus further comprises a plurality of rows, wherein solar modulesof alternating rows are oriented at tilt angles of the opposite degreeto form a peaked structure. In some embodiments, the face is joined tothe tab by clinching.

In another aspect, a portable apparatus responsible for orchestratingcomponent assembly and installation into the ground, is also disclosed.Depending upon the particular embodiment, the portable apparatus may bedisposed in a truck (e.g., upon a platform of a truck bed), within atrailer, or may take the form of a specially-built vehicle designed forthis specific purpose.

In some aspects, the present disclosure describes a method comprising,at a first location of an installation site, inserting a portion (e.g.,a tapered point) of a lower end of a first post into the ground. In someembodiments, the portion of the lower end of the first post may not orneed not be tapered. In some embodiments, the method further comprisesattaching a first clip to a frame of a first solar module. In someembodiments, the method further comprises joining the first clip to anupper end of the first post. In some embodiments, the method furthercomprises moving in a linear direction to a second location of theinstallation site. In some embodiments, the method further comprises atthe second location of the installation site, inserting a portion of alower end of a second post into the ground. In some embodiments, themethod further comprises attaching a second clip to a frame of a secondsolar module. In some embodiments, the method further comprises joiningthe second clip to an upper end of the second post. In some embodiments,the method further comprises moving in the linear direction to a thirdlocation of the installation site. In some embodiments, the portion ispushed into the ground. In some embodiments, the tapered point is pushedinto the ground by a hydraulic actuator. In some embodiments, theportion is screwed into the ground. In some embodiments, the first clipis attached to the frame by lowering the first solar module. In somenon-limiting embodiments, the solar modules may be raised or lower usinga conveyor (e.g., a vertical conveyor). In some embodiments, the firstpost is joined to the first clip by a tool (e.g., a forming tool or aclinching tool). In some embodiments, the second post is joined to thesecond clip by the tool. In some embodiments, the method furthercomprises storing the first solar module, the second solar module, thefirst clip, and/or the second clip in a mobile installation apparatus.In some embodiments, the tool is secured to the mobile installationapparatus.

In some aspects, the present disclosure describes an apparatuscomprising a platform on a vehicle. In some embodiments, the apparatusfurther comprises an actuator fixed to the platform and configured toinsert a post into the ground at a first location of an installationsite. In some embodiments, the apparatus further comprises a verticalconveyor fixed to the platform and configured to dispense to a loadhead, a solar module having a frame. In some embodiments, the apparatusfurther comprises the load head on the platform and configured toposition a clip attached to the frame, proximate to the post. In someembodiments, the apparatus further comprises a tool fixed to theplatform and configured to join the clip to the post. In someembodiments, the vehicle comprises a truck, a trailer, or aspecially-built device. In some embodiments, the platform comprises atwo-way table. In some embodiments, the apparatus further comprises acontroller including at least one of a camera and a Global PositioningSystem (GPS) configured to determine a position of the two-way table. Insome embodiments, the tool comprises a clinching tool. In someembodiments, the actuator comprises a hydraulic actuator configured topush a portion (e.g., a tapered point) of the post into the ground. Insome embodiments, the vertical conveyor is configured to lower the solarmodule onto the clip in order to attach the clip to the frame. Inanother non-limiting embodiments, the present disclosure provides asystem comprising one or more mobile platforms. A plurality of modulesmay be stacked on a mobile platform (e.g., a module installer), and oneor more modules may be handled or moved by a piece of automationassociated with the module installer (e.g., a robotic arm, a member, orany mechanical or structural component). The one or more modules may bemoved using geolocation data and/or machine or sensor vision to alocation in which one or more posts have been placed (e.g., by a mobilepost installer). The one or more modules may then be installed on theone or more posts.

In another aspect, the present disclosure provides a support structurecomprising a sheet metal that is shaped or bent to enable high densitypacking of the support structure. In some embodiments, the sheet metalcomprises one or more curved or angled portions or sections. In someembodiments, the support structure further comprises one or more tabsproviding a surface for connecting the sheet metal or a portion thereofto a solar module or a bracket affixable to the solar module. In someembodiments, the sheet metal is shaped or bent in a Z shape or a Cshape. In some embodiments, the one or more tabs are integrated with orcoupled to the sheet metal. In some embodiments, the sheet metalcomprises the one or more tabs. In some embodiments, the one or moretabs correspond to a portion or a section of the sheet metal. In someembodiments, the sheet metal comprises one or more holes to allow for aninterface for a tool. In some embodiments, the one or more holes are cutout of the sheet metal to reduce a weight of the support structure. Insome embodiments, the sheet metal comprises the one or more tabs. Insome embodiments, the one or more tabs are configured to flare out froma lower portion of the sheet metal. In some embodiments, at least aportion of the sheet metal is tapered to increase tip stress while thesupport structure is driven into the ground. In some embodiments, thesheet metal comprises one or more features that are engageable by adriving unit to drive the support structure into the ground. In someembodiments, the one or more features comprise a hole. In someembodiments, the one or more features comprise a protrusion. In someembodiments, the one or more features are positioned at a predeterminedlocation between a first end and a second end of the sheet metal. Insome embodiments, the one or more features permit the driving unit todrive the support structure into the ground by exerting a force at ornear the predetermined location. In some embodiments, the supportstructure is stackable or arrangeable in one or more stacks or bundles.In some embodiments, the one or more tabs comprise a cutout feature forhanging the support structure from a hanger or a rack.

Another aspect of the present disclosure provides a non-transitorycomputer readable medium comprising machine executable code that, uponexecution by one or more computer processors, implements any of themethods above or elsewhere herein.

Another aspect of the present disclosure provides a system comprisingone or more computer processors and computer memory coupled thereto. Thecomputer memory comprises machine executable code that, upon executionby the one or more computer processors, implements any of the methodsabove or elsewhere herein.

Additional aspects and advantages of the present disclosure will becomereadily apparent to those skilled in this art from the followingdetailed description, wherein only illustrative embodiments of thepresent disclosure are shown and described. As will be realized, thepresent disclosure is capable of other and different embodiments, andits several details are capable of modifications in various obviousrespects, all without departing from the disclosure. Accordingly, thedrawings and description are to be regarded as illustrative in nature,and not as restrictive.

INCORPORATION BY REFERENCE

All publications, patents, and patent applications mentioned in thisspecification are herein incorporated by reference to the same extent asif each individual publication, patent, or patent application wasspecifically and individually indicated to be incorporated by reference.To the extent publications and patents or patent applicationsincorporated by reference contradict the disclosure contained in thespecification, the specification is intended to supersede and/or takeprecedence over any such contradictory material.

BRIEF DESCRIPTION OF THE DRAWINGS

The novel features of the invention are set forth with particularity inthe appended claims. A better understanding of the features andadvantages of the present invention will be obtained by reference to thefollowing detailed description that sets forth illustrative embodiments,in which the principles of the invention are utilized, and theaccompanying drawings (also “Figure” and “FIG.” herein), of which:

FIG. 1 is a simplified force diagram of a system for ground mount ofsolar panels.

FIG. 2 shows a simplified view of an embodiment of a ground mountsystem.

FIG. 3 shows a simplified view of a conventional ground mountinstallation.

FIG. 4A shows a perspective view of a ground mount system according toan embodiment.

FIG. 4B is an end view of the ground mount system of FIG. 4B, showingloading forces.

FIG. 4C shows an enlarged view of a post according to an embodiment.

FIG. 5A shows a perspective view of a ground mount system according toan alternative embodiment.

FIG. 5B shows is a simplified end view of the embodiment of FIG. 5Ashowing loading forces.

FIG. 6A is a perspective of a solar module array resulting from a groundmount system according to an embodiment.

FIG. 6B is a perspective view of another solar module array resultingfrom a ground mount system according to an embodiment.

FIG. 6C shows a perspective view of an alternative embodiment withportrait-oriented solar modules with short ends aligned in the rowdirection.

FIG. 7A shows a perspective view of an end clip according to anembodiment.

FIG. 7B shows a perspective view of an end clip with two modulesattached.

FIG. 8A shows a perspective view of a corner clip according to anembodiment.

FIG. 8B shows a perspective view of the corner clip embodiment connectedto two modules and a post.

FIG. 8C shows a perspective view of a pair of corner clips and attachedmodules, connected to a post.

FIG. 9 illustrates forces to which a ground mount system may besubjected.

FIG. 10 shows main tolerances of concern for a ground mountinstallation.

FIG. 10A shows a perspective view of two clips clinched in place onto apost.

FIG. 10B is a side perspective view showing the impact of terrain uponinstallation.

FIG. 10C is an enlarged view showing the ability of a ground mountsystem according to embodiments, to handle relatively high tolerances.

FIG. 10D shows a perspective view of an alternative post embodiment.

FIG. 11 shows an enlarged perspective view of the spacing betweenmodules.

FIG. 12 shows a simplified view of an alternative clip structure.

FIG. 13 is a simplified view showing a clip attached to the side of amodule.

FIG. 14 is a simplified perspective view showing the clip/moduleassembly, adjacent to an alternative embodiment of a post.

FIG. 15 is a simplified view showing a clinching tool that can be usedto clinch together the clip to a face of the post.

FIG. 15A shows a simplified view of a resulting clinching joint.

FIG. 15B shows a view of a post according to an alternative embodiment.

FIG. 15C shows fabricated posts maintained in a bandoliered structureafter progressive stamping.

FIG. 16 is a simplified view showing a corner of four modules that jointo one post.

FIG. 17 shows a progressive stamping manufacturing process that can beused to fabricate the clip.

FIG. 18 shows how the clip can maintain its connected orientation in anintegrated bandolier configuration after formation.

FIG. 19 shows another embodiment of a ground mounting system.

FIG. 20 shows a typical layout of standard blocks of solar modules inthis connected orientation.

FIG. 21 shows how four of the blocks of FIG. 20 connect to one centralinverter.

FIG. 22 is a perspective view of a portion of a block.

FIG. 23 is a simplified flow diagram illustrating a supply chain that ismade available according to embodiments.

FIG. 24 is a simplified overhead view showing progress of one embodimentof an installation machine over a site.

FIG. 25 is a simplified overhead view showing progress of an alternativeembodiment of an installation machine 2500 over a site

FIG. 26 provides a formal coordinate system for describing a movingvehicle.

FIG. 27 shows a rear perspective view of one embodiment 2700 of theinstallation apparatus.

FIG. 28 shows a detail of the vertical conveyor element which can beused to lower modules one at a time.

FIG. 29 is a schematic view showing how standard packaging of a stack ofsolar modules, can be loaded on to vertical conveyors and loweredmodule-by-module onto sheet metal joints.

FIG. 30 shows a detail of a module lowered onto a joint.

FIG. 31 shows a side view of a stack of solar modules on a verticalconveyor.

FIG. 32 shows a front perspective view of an installation apparatus.

FIG. 33 shows a view of the load head frame connected to the actuatortip.

FIG. 34 shows approaches for controlling position of a moveableplatform.

FIG. 35 shows a front perspective view of an installation apparatusaccording to an alternative embodiment.

FIG. 36 shows an enlarged side view of the apparatus of FIG. 35 .

FIG. 37A shows a perspective view of an alternative embodiment.

FIG. 37B shows an enlarged view of a gantry.

FIG. 37C shows an enlarged view of a rotational gear.

FIG. 38A shows a perspective view of another alternative embodiment.

FIG. 38B shows movement in various directions of the embodiment of FIG.38A.

FIG. 39 shows an overhead view of an alternative embodiment featuring acleaning robot.

FIG. 40 shows an overhead view of an alternative embodiment featuringstaggered module placement.

FIG. 41 shows an overhead view of an alternative embodiment featuringstaggered module placement and post location.

FIG. 42 shows an overhead view of an autonomous system for positioningand assembling solar modules, in accordance with some embodiments. Insome cases, modules may be unboxed, inspected, and/or processed with orwithout attachments before transporting around a site. In some cases,post installers may drive posts and continuously reload from factorbundled packs. In some cases, module installers may pull a solar modulefrom a stack and attach them to posts. In some cases, posts may beinstalled by a custom machine on the back of a tractor or any other typeof vehicle (e.g., any type of autonomous or semi-autonomous towingvehicle). In some cases, a module may be installed on a previouslyinstalled post by a machine on the back of a different tractor.

FIG. 43 shows an overhead view of an autonomous system for positioningand assembling solar modules, in accordance with some embodiments. Insome cases, tractors may be fully electric. In some cases, a mobilepower unit may be disposed at or near a site where tractors may charge.In some cases, the mobile power unit may be comprise solar panels and/orbatteries. In some cases, a reloading unit may travel between stations.In some cases, a reloading unit may carry posts, solar modules, or anycombination thereof. In some cases, a reloading unit may travel betweena prep station and active installer units (e.g., tractors).

FIGS. 44A-44M show vehicles for positioning and assembling solarmodules, in accordance with some embodiments. In some cases, a moduleinstaller may be a custom machine built on a tractor. In some cases, amodule installer may take in a stack of solar modules. In some cases,the stack of solar modules may be placed on the module installer. Insome cases, the stack of solar modules may be picked up by the moduleinstaller. In some cases, the module installer may carry the stack ofmodules. In some case, the module installer may separate one module fromthe stack of modules. In some cases, the module installer may positionthe one module over a plurality of installed posts, for example, two,three, or four installed posts. In some cases, the module installer maylower the module into a predetermined position over the plurality ofinstalled posts. In some cases, the module installer may deform ametallic portion of a module to create a rigid connection between themodule and the post. In some cases, the module installer may release themodule. In some cases, the module installer may test a strength ofconnections formed between the module and the plurality of posts bylifting, pushing, twisting, or any sufficient force. In some cases, themodule installer may drive to a next location to place a module. In somecases, a module installer may comprise 3, 4, 5, or 6 degrees of motionor more. In some cases, a module installer may comprise a robot arm thatis configured to receive a module from a flipping machine. In somecases, a robot arm may be used to reach pick up a module from a stack.In some cases, a gantry may be used to tilt back and forth to pick up amodule and position the module behind. In some cases, a double rotarymotion manipulator comprise 1, 2, or more rotating joints may be used toposition a module above one or more posts. In some cases, a trailer maycomprise a gantry for picking up and positioning one or more modulesabove posts.

FIGS. 45A-45D show perspective views of a machine for installing posts,in accordance with some embodiments. In some cases, the machine maycomprise 3, 4, 5, or 6 degrees of freedom or more. In some cases, themachine may autonomously position a post, install the post in theground, and/or force-test the post by pulling on it laterally,vertically, or any other direction and record the force-test data. Insome cases, the machine may be configured to carry one or more bundlesof posts on a rack. In some cases, the machine may be configured tolocate one or more posts in a bundle of posts and collect a new post ona driving bit.

FIGS. 46A-46B show a machine for installing posts, in accordance withsome embodiments. In some cases, the machine may have 3 or more mountinginterfaces to mount a tractor to, for example, using a 3 point hitch. Insome cases, the machine may carry a hammer for pounding a post into theground. In some cases, a hammer may be mounted on vertical rails and maybe free to slide vertically or in any other sufficient direction suchthat sufficiently small or no vibration is transferred from the hammerto the remainder of the machine.

FIGS. 47A-47I show coupling mechanisms between a driving bit and a post,in accordance with some embodiments. In some cases, a driving bit may beconnected to a hammer. In some cases, a driving bit may comprise a shearinterface for engaging a post during the pounding. In some cases, adriving bit may comprise a retention feature which prevents a post fromfalling off of the bit while it is being positioned and driven. In somecases, a driving bit may be configured to allow a post to be poundedfrom the post's web, which may be disposed lower on the body of thepost. In some cases, pounding from the web may allow the hammer toimpact the post with greater force, as compared to impacting from thehead, because pounding from the web may effectively lower the bucklinglength of the post during pounding. In some cases, a driving bit mayenter a larger portion of a hole in a post. In some cases, a driving bitmay slide down in a configuration and retain against a chisel bit. Insome cases, a head of a chisel feature on a driving bit may overlap withat least a portion of a post when the driving bit is engaged with thepost. In some cases, there may be 1, 2, 3, 4, or more shear features ona chisel bit. In some cases, a chisel bit may also be used as aretention feature. In some cases, a feature on a chisel bit may retain apost. In some cases, a feature on a chisel bit may be separate from afeature that is pounding the post. In some cases, a retention featuremay be a clocking element that rotates to engage with a post. In somecases, a retention feature may be a clocking square that turns about 45degrees such that the corners retain a post once engage. In some cases,a retention feature may overhang a hole in the post. In some cases, ashaft may not engage a bottom of a hole in the post. In some cases, aping may engage with a post without overhanging.

FIGS. 48A-48B show a comparison of driving a post using differentcoupling mechanisms, in accordance with some embodiments.

FIGS. 49A-49C show posts, in accordance with some embodiments.

FIGS. 50A-50C show coupling mechanisms between posts and a rack, inaccordance with some embodiments. In some cases, a post may comprise a Zshaped section or a Z shape. In some cases, a post may comprise a shapethat is substantially stackable. In some cases, a post may comprise oneor more oblique set of tabs at the top. In some cases, a tab maycomprise a cutout feature. In some cases, a cutout feature may beconfigured to allow a post to be hung from a hanger or a rack. In somecases, one or more posts may be bundled and shipped in a container or bedisposed on a machine.

FIG. 51 illustrates a method for coupling a solar module and brackets,in accordance with some embodiments. In some cases, a bracket may beinstalled by a process in a station where modules are unboxed,inspected, and/or then placed on a tooling jig. In some cases, 1, 2, 3,4, or more rivet guns may install rivets to join a bracket to a solarmodule from below, side, top, or any sufficient direction. In somecases, a clinching tool or an impact driver (e.g., for torquing nuts)may be used instead of a rivet gun.

FIG. 52 illustrates a method for autonomously positioning and assemblingsolar modules, in accordance with some embodiments. In some case, amodule installer may drive to a location. In some cases, a moduleinstaller may pick up a module. In some cases, a module installer mayposition the module over 1, 2, 3, 4, or more posts. In some cases, aclinch tool may be used to form a connection between the module and theone or more posts. In some cases, the clinch tool may fit between earsof a post and a clip. In some cases, the clinch tool may close to form ajoint. In some cases, the module installer may release the clinch tool.In some cases, an end effector may be used to lift off a module. In somecases, a module installer may drive to the next set of one or more poststo install a next module.

FIG. 53 illustrates a plurality of brackets that can be coupled to oneor more posts, in accordance with some embodiments. In some cases, asolar module may comprise a bracket. The bracket may be attached orcoupled to the solar module. In some cases, the bracket may comprise adeformable metal. In some cases, a connection may be formed between thebracket and a post. In some cases, the connection may be formed byclinching the bracket and the post together. In some cases, the bracketmay comprise a flat or an angled piece of metal that is configured torivet onto a module, for example, through mounting holes. In some cases,the bracket may be connected to a module by clinching the bracket to theframe of a module.

FIGS. 54A-54C illustrates a method for determining a landscape topologyfor positioning and assembling solar modules, in accordance with someembodiments. In some cases, the method may comprise analyzing a terraintopology and/or GIS data of a given terrain. In some cases, the methodmay comprise processing a curvature of the terrain topology or GIS data.In some cases, the method may comprise simulating posts and modulesinstalled on the given terrain. In some cases, the method may compriseuploading the posts and the modules geolocation position andconstruction data for one or more machines for installing the posts andthe modules.

FIG. 55 illustrates a GUI for determining a landscape topology forpositioning and assembling solar modules, in accordance with someembodiments.

FIG. 56 illustrates a module comprising a fixed tilt array, inaccordance with some embodiments. In some cases, the module may berigidly connected to two posts. In some cases, the module may comprise asmall support bracket that is mounted directly to a post withoutrequiring a spanning intermediate structure. In some cases, a module maybe driven by a 90 degree linkage where each module may be driven to arequired angle, for example, without requiring an entire tracker ‘table’being driven together. In some cases, a module may spans two or moreposts without need for an intermediate structure between posts. In somecases, modules may be connected with a continuous wire or chain. In somecases, the continuous wire or chain may be driven by a mechanism totrack the solar modules about one or more pivots on the posts. In somecases, the modules may each comprise an individual drive or drive unitsuch that each module may independently track the sun.

FIG. 57 illustrates a solar tracker, in accordance with someembodiments.

FIG. 58 illustrates a tracking unit, in accordance with someembodiments. In some cases, a tracking unit may be autonomouslydeployed. In some cases, a tracking unit may be pre-assembled,distributed, and placed on a field. In some cases, a tracking unit maybe wired autonomously using geolocation data and/or any machinedisclosed herein. In some cases, the installed tracking unit may expandto a single module solar track for tracking the sun in 1, 2, or 3 axes.

FIG. 59 illustrates a light curtain, in accordance with someembodiments. In some cases, a machine may comprise one or more opticalsensors configured to detect when a foreign object (e.g., a human oranother agent) enters a workspace defined by a light curtain.

FIG. 60 illustrates solar module array configurations, in accordancewith some embodiments. In some cases, a solar module array may comprise4 posts for each corner of a module. In some cases, a solar module arraymay comprise 2 posts along a middle axis of a module.

FIG. 61 shows a computer system, in accordance with some embodiments.

FIG. 62 illustrates an alternative embodiment of an exemplary vehiclethat can be used or configured to handle, transport, install, or deployone or more solar modules.

FIG. 63 illustrates another alternative embodiment of an exemplaryvehicle that can be used or configured to handle, transport, install, ordeploy one or more solar modules.

FIG. 64 illustrates an end-effector with clinch tools positioned at thecorners of the end-effector, in accordance with some embodiments.

FIG. 65 illustrates a bottom portion of the clinch tools which can betapered to help the clinch tools locate or engage with a module.

FIGS. 66A and 66B illustrate an alternate embodiment of a clip, inaccordance with some embodiments.

FIG. 67 illustrates an alternative embodiment of a module installervehicle, in accordance with some embodiments.

FIG. 68 illustrates an exemplary configuration for a post, in accordancewith some embodiments.

FIGS. 69A and 69B illustrate an alternative embodiment of the clipsdescribed herein, in accordance with some embodiments.

FIG. 70A illustrates an additional sheet metal feature that can be usedto retain one or more lead wires or wire leads of a solar module andhold them fixed in a specific side of the module, for later handling orprocessing.

FIG. 70B illustrates an embodiment of a clip where the module wire leadis connected to the clip that is also connected to the module and thatwill be connected to the post.

FIG. 70C illustrates using an additional tool to autonomously take thesolar module wire leads that are held in place by the clip and connectthem to each other to form an electrical connection between the modules.

FIG. 71 illustrates an alternative embodiment of the tool and method inFIGS. 70A, 70B, and 70C, whereby the tool does not push two connectorstogether, and instead cuts, strips, and splices the wires together inplace without the use of a connector.

FIG. 72 and FIG. 73 illustrate an exemplary configuration in which aplurality of modules are positioned at a 90 degree orientation relativeto the ground.

FIG. 74 illustrates an example of a middle clip, in accordance with someembodiments.

FIG. 75 illustrates a removable access trough that can be placed on topof posts in the valley or peaks of a solar module array.

FIG. 76 and FIG. 77 illustrate a gantry on wheels that can drive on theground in the gaps between the array in certain configurations.

DETAILED DESCRIPTION

While various embodiments of the invention have been shown and describedherein, it will be obvious to those skilled in the art that suchembodiments are provided by way of example only. Numerous variations,changes, and substitutions may occur to those skilled in the art withoutdeparting from the invention. It should be understood that variousalternatives to the embodiments of the invention described herein may beemployed.

Whenever the term “at least,” “greater than,” or “greater than or equalto” precedes the first numerical value in a series of two or morenumerical values, the term “at least,” “greater than” or “greater thanor equal to” applies to each of the numerical values in that series ofnumerical values. For example, greater than or equal to 1, 2, or 3 isequivalent to greater than or equal to 1, greater than or equal to 2, orgreater than or equal to 3.

Whenever the term “no more than,” “less than,” or “less than or equalto” precedes the first numerical value in a series of two or morenumerical values, the term “no more than,” “less than,” or “less than orequal to” applies to each of the numerical values in that series ofnumerical values. For example, less than or equal to 3, 2, or 1 isequivalent to less than or equal to 3, less than or equal to 2, or lessthan or equal to 1.

The term “real time” or “real-time,” as used interchangeably herein,generally refers to an event (e.g., an operation, a process, a method, atechnique, a computation, a calculation, an analysis, a visualization,an optimization, etc.) that is performed using recently obtained (e.g.,collected or received) data. In some cases, a real time event may beperformed almost immediately or within a short enough time span, such aswithin at least 0.0001 millisecond (ms), 0.0005 ms, 0.001 ms, 0.005 ms,0.01 ms, 0.05 ms, 0.1 ms, 0.5 ms, 1 ms, 5 ms, 0.01 seconds, 0.05seconds, 0.1 seconds, 0.5 seconds, 1 second, or more. In some cases, areal time event may be performed almost immediately or within a shortenough time span, such as within at most 1 second, 0.5 seconds, 0.1seconds, 0.05 seconds, 0.01 seconds, 5 ms, 1 ms, 0.5 ms, 0.1 ms, 0.05ms, 0.01 ms, 0.005 ms, 0.001 ms, 0.0005 ms, 0.0001 ms, or less.

In an aspect, the present disclosure provides systems and methods forhandling and deploying energy modules. The energy modules may comprise asolar module or a plurality of solar modules. The solar modules maycomprise a deployable device that is configured to generate energy usingone or more resources. In some cases, the one or more resources maycomprise solar energy, heat energy, radiation energy, or any other typeof energy.

In one aspect, the present disclosure provides a method for handling ordeploying a solar module. The method may comprise using at least onerobot to fully autonomously position and assemble (i) at least one solarmodule and (ii) its supporting structure at a sensed geolocation,without aid from a user. In some cases, a plurality of robots may beused to autonomously position and deploy, install, or assemble aplurality of solar modules and/or one or more supporting structures forthe plurality of solar modules.

In some cases, a robot may refer to any machine capable of performingone or more tasks. In some cases, the robot may perform the one or moretasks autonomously (e.g., without human intervention or without externalintervention from another entity) or semi-autonomously (e.g., withminimal external supervision, instruction, or intervention).

In some cases, a task may comprise transporting various components to beused for deploying an energy module as disclosed herein, for example, anenergy module or a post. In some cases, a task may comprise installingvarious components for building an energy module disclosed herein, forexample, installing a post on the ground or connecting an energy moduleto a given post. In some cases, a task may comprise handling anddeploying an energy module.

In some cases, the robot may comprise one or more movable members. Insome cases, the movable members may comprise an arm or an end effector.The movable members may be configured to handle, move, or deploy theenergy modules.

In some cases, the robot may comprise one or more energy storage devices(e.g., a battery). In some cases, the one or more energy storage devicesmay be chargeable by a renewable energy system. In some embodiments, oneor more electric charging stations may be provided and distributedacross a terrain for enabling charging of one or more robots. The one ormore robots may comprise, for example, a mobile platform, a vehicle, orany other machine as described elsewhere herein. In some embodiments,the one or more electric charging stations can be mobile. In such cases,the electric charging stations may be configured to travel to a robot orvehicle that needs to be charged. In other embodiments, the one or moreelectric charging stations can be stationary. In such cases, one or morerobots or vehicles may be configured to travel to the one or moreelectric charging stations for charging.

In some cases, the robot may comprise a vehicle. In some cases, thevehicle may comprise one or more wheels, one or more legs, or any othermember configured to transport the robot on flat or non-flat terrain.

In some cases, the robot may comprise one or more vision sensors. Insome cases, the robot may perform a task based at least in part oninformation provided through the one or more vision sensors.

In some cases, the robot may comprise one or more computers, processors,or logic circuits in operable communication with one or more computers,processors, or logic circuits of another robot, or one or more servers(e.g., a cloud server).

In some cases, a plurality of robots may be used to autonomouslyposition and deploy a plurality of posts configured to support theplurality of solar modules. The solar modules may be affixed to one ormore posts. FIG. 4C shows an enlarged view of a post 450 according to anembodiment. In some cases, the post may comprise a flat top interface452 to offer a clinching surface for the clip. In some cases, the postmay be fabricated from sheet metal (e.g., provided in a coil). In somecases, a lower portion of the post may include a sawtooth pattern 454that is cut to impart resistance from being pulled out from the ground.In some cases, an exemplary post may be −3 ft long, with one 1 ftexposed out of ground, and 2 ft projecting into the ground. In somenon-limiting embodiments, the post may have a length ranging from about1 ft to about 10 ft.

In some embodiments, the post may comprise a pointed end 456 forefficient driving into the ground—e.g., by (hydraulic) pushing. In somecases, the degree of tapering of this end can be determined toaccommodate the shape of a corresponding tip of a next post in the coil,thereby conserving sheet metal material and reducing cost.

In some cases, the presently disclosed embodiments may allow forvertical adjustment of the dimension of the post protruding aboveground. In some cases, the vertical adjustment may be accomplished bypushing deeper or by adding an upper attachment to increase post height.

In some cases, a robot may install a first post at a first location anda second post at a second location. In some cases, the first locationand the second location may be sufficiently close such that an energymodule may be installed to be supported by both the first post and thesecond post. In some cases, two separate energy modules may be installedto be supported by each of the first post and the second post,respectively. In some cases, the first post may be installed first, andthe second post may be installed second. In some cases, the first postand the second post may be installed substantially at about the sametime. In some cases, a first robot may install a first post at a firstlocation and a second robot may install a second post at a secondlocation. Various number of posts may be installed by a given robot. Oneor more posts may be installed at various locations by a given robot.

In some cases, the plurality of robots may be configured to operate as afleet or a swarm. The plurality of robots may communicate with one ormore servers configured to control an operation or a movement of theplurality of robots within an area or location comprising the sensedgeolocation. The server may provide different commands to differentrobots, or command different robots to collaboratively perform one ormore tasks. It shall be understood that the coordination of one or morerobots may be implemented in various configurations to achieve a similareffect, for example, by using various number of robots, various types ofrobots, various number of posts, and various rulesets or algorithms forcoordinating the robots.

In some cases, the plurality of robots may be configured to operate in acoordinated manner such that a time taken to perform the one or moretasks is optimized. For instance, a first set of robot(s) may coordinateto install one or more posts at a first location and then immediately ata second location. A second set of robot(s) may coordinate with thefirst set of robot(s) to install a solar module at the first locationimmediately as the one or more posts are installed at the firstlocation. In some cases, the first location may be a region near therobot. In some cases, the first location may be a region near where thesolar module is stored. In some cases, the second location may be nearthe first location. In some cases, the second location may be ageo-sensed location (e.g., a location that is determined or identifiedusing one or more positions sensors and/or geographical or topologicaldata). In some cases, the second location may be an approximatelocation, and the approximate location may be adjusted in real-time tobe a more precise location.

In some cases, the method may comprise using the at least one robot tofully autonomously position and assemble the at least one solar moduleand its supporting structure in two or more different directions. Thetwo or more different directions may comprise a first direction and asecond direction. The first direction and the second direction may beparallel to each other. Alternatively, the first direction and thesecond direction may be disposed at an angle relative to each other. Theangle may range from 0 degrees to 180 degrees.

In some cases, the at least one robot may use a movable member to handlethe solar module or any components or supporting structures thereof. Insome cases, the at least one robot may move the solar module or anycomponents or supporting structures thereof by translating along one,two, or three Euclidean dimensions. In some cases, the at least onerobot may move the solar module or any components or supportingstructures thereof by rotating the solar module around one, two, orthree axes of the solar module. In some cases, the at least one robotmay translate and rotate the solar module simultaneously. In some cases,the at least one robot may translate the solar module and then rotatethe solar module subsequently, or vice versa. In some cases, for a solarmodule that is substantially rectangular in shape, an axis of a solarmodule may be defined as the normal direction from the plane of thesolar module having the largest area, the plane of the solar modulehaving the second largest area, or the plane of the solar module havingthe third largest plane. The at least one robot may move the solarmodule in various ways, including changing a position and/or anorientation of the solar module or the components of the solar module.

In some cases, the solar module, supporting structures, and anycomponents thereof may be repositioned and/or re-oriented to be moreprecise and/or ensure proper installation during deployment. In somecases, a given post may be repositioned and/or re-oriented to ensure asuccessful insertion of the post into the ground.

FIG. 52 illustrates an exemplary method for autonomously positioning andassembling solar modules, in accordance with some embodiments. In somecases, a module installer (e.g., a robot) may drive to a location. Thelocation may be determined by a user or an operator of the robot, orbased on sensor data. In some cases, a module installer may pick up anenergy module (e.g., a solar module). In some cases, a module installermay position the module over 1, 2, 3, 4, or more posts. The posts may beinstalled autonomously by another robot.

In some cases, a clinch tool may be used to form a connection betweenthe modules and the one or more posts, as described in greater detailbelow. In some cases, the clinch tool may fit between ears of a post anda clip. In some cases, the clinch tool may close to form a joint. Insome cases, the module installer may release the clinch tool. In somecases, an end effector may be used to handle the tool and/or install themodule. In some cases, a module installer may drive to another set ofone or more posts to install another module.

In some embodiments, the method may comprise using the at least onerobot to fully autonomously position and assemble a plurality of solarmodules and associated supporting structures to construct a solar modulearray. In some cases, the plurality of solar modules and the associatedsupporting structures may comprise at least one solar module and asupporting structure for the at least one solar module.

In some cases, an array of modules, solar modules, energy modules, andthe like may refer to an arrangement of a plurality of solar modulesacross an area or region. In some cases, the arrangement may be alateral arrangement. In some cases, the arrangement may comprise aplurality of rows and/or columns. In some cases, the arrangement maycomprise a circular pattern and/or a ring configuration. In some cases,the arrangement may comprise a hexagonal (e.g., honeycomb) pattern. Insome cases, the arrangement may comprise a random configuration. In somecases, the arrangement may be based at least in part on the terrain ortopology of the area or region in which the array is or will bedeployed.

In some cases, the solar module arrays and/or various supportingstructures (e.g., posts) can be constructed, deployed, or installed on asubstantially flat terrain. In some cases, the solar module arrays canbe constructed on a substantially non-flat terrain. The terrain on whichthe solar module arrays and/or the various supporting structures (e.g.,posts) are constructed, deployed, or installed can comprise, forexample, sand soil, rocks, water, ice, vegetation, grass, or any othermanmade or natural surface. In some cases, the terrain may comprise acanyon, a desert, a forest, a glacier, a hill, a marsh, a mountain, avalley, an oasis, an ocean or other body of water, open terrain, a riverterrain, a swamp terrain, or a tundra terrain.

In some cases, the terrain may comprise one or more flat portions and/orone or more inclined portions. In some embodiments, the inclinedportions may have a slope ranging from about 1 degree to about 30degrees or more.

FIG. 60 illustrates various solar module array configurations, inaccordance with some embodiments. In some cases, the solar module arraymay comprise 4 posts for each corner of a module. In some cases, thesolar module array may comprise 2 posts along a middle axis of a module.In some cases, the solar module array may be a complete wired array. Insome cases, the solar module array may be a dual-tilt array. In somecases, the solar module array may be a fixed tilt array. In some cases,one or more modules of the array may comprise a support bracket that ismounted directly to a post without requiring a spanning intermediatestructure. In some cases, one or more modules may span two or more postswithout the need for an intermediate structure between posts. FIG. 72and FIG. 73 illustrate an exemplary configuration in which a pluralityof modules are positioned at a 90 degree orientation relative to theground. In some cases, the solar modules may be tilted to a full 90degrees. In some cases, a plurality of posts may be affixed to one ormore sides of the solar modules. In some cases, the arrangement and/orthe configuration of the solar modules may permit access to the spacesbetween various rows in a solar module array. In some cases, the spacesbetween the various rows in the array may be used for growing crops. Theposts, clips, and modules may be placed, installed, or deployed inaccordance with any of the embodiments, methods, and/or systemconfigurations shown and described herein.

In some cases, the modules may be configured to independently track thesun. Tracking the sun may comprise moving, repositioning, or reorientingthe modules so that a working surface of the modules is able to receiveone or more rays of light from the sun.

In some cases, the modules may track the sun based at least in part on aforecast, the location of the modules, or both. In some cases, themodules may track the sun based at least in part on a measured signal,e.g., amount of energy or power generated by the modules.

In some cases, the modules may each comprise an individual drive suchthat each module may independently track the sun. In some cases, themodules may be connected with a continuous wire or chain. The continuouswire or chain may be driven by a mechanism (e.g., one or more motors) totrack the solar modules about one or more pivots on the posts. In somecases, the modules may be driven by a linkage (e.g., a 90 degreelinkage) to a required angle, without requiring a tracking unit or atracking table.

In some cases, one or more mechanisms may be disposed on one end of anarray of solar modules. In some cases, one or more mechanisms may bedisposed on two opposite ends of an array of solar modules. In somecases, one or more mechanisms may be disposed among the solar modules inthe array. Any sufficient number of mechanisms may be disposed among thesolar modules, and any sufficient arrangement of mechanisms may bedisposed among the solar modules.

FIG. 57 illustrates a solar tracker, in accordance with someembodiments. The solar tracker may comprise a solar module sun trackingcapabilities and/or a mechanism for moving one or more portions orcomponents of a solar module to track the sun.

In some cases, an array of solar modules may comprise a plurality ofsolar modules disposed substantially linearly in at least one direction.In some cases, the linearly disposed plurality of solar modules may becoupled with one or more cables or chains along the linear direction. Insome cases, the one or more cables or chains may be pulled along thelinear direction, such that the plurality of solar modules arereoriented and/or repositioned.

In some cases, the plurality of solar modules may be disposedsubstantially linearly in at least two directions. In some cases, theplurality of solar modules may be coupled with at least two sets of oneor more cables or chains along the at least two directions,respectively. In some cases, a first set of the one or more cables maybe pulled along a first linear direction to reorient and/or repositionthe plurality of solar modules in a first direction. In some cases, asecond set of the one or more cables may be pulled along a second lineardirection to reorient and/or reposition the plurality of solar modulesin a second direction.

In some cases, the one or more cables or chains may be coupled above orbelow a given solar module. In some cases, the one or more cables orchains may be coupled to the side of a given solar module.

FIG. 58 illustrates a tracking unit, in accordance with someembodiments. The tracking unit may comprise a solar module with suntracking capabilities and/or a mechanism for moving one or more portionsor components of a solar module to track the sun.

In some cases, the tracking unit may be autonomously deployed. In somecases, the tracking unit may be pre-assembled, distributed, and placedon a field. In some cases, the tracking unit may be positioned,deployed, or wired autonomously using geolocation data and/or anymachine or robot disclosed herein. In some cases, the tracking unit maybe expandable to a single module solar track for tracking the sun inone, two, three, or more axes.

The methods disclosed herein may be implemented using a ground mountsystem for solar panels. The ground mount system may comprise a system,a structure, or a plurality of components configured to support orstabilize an energy module when the energy module is deployed.

FIG. 1 is a simplified force diagram of a system 100 for ground mountingsolar panels, in accordance with some embodiments. Here, the activephotovoltaic (PV) materials and any associated components (frames,beams, pillars, superstructure, junction boxes, wiring) represent aphysical load G 102 that may be safely and reliably supported above theground 104 against at least the force of gravity, as well as againstpossible external forces (e.g., wind, seismic).

FIG. 2 shows a simplified view of an embodiment 200 of a ground mountsystem for solar modules, in accordance with some embodiments. Here, aplurality of solar modules 202 are reliably supported above the ground204 by a plurality of posts 206. In some cases, no separate and distinctsuperstructure may be needed. In some cases, these posts may berelatively small in size, and can be installed with a high frequency f.In some cases, each post may bear a much smaller portion of the overallload. Moreover, for the embodiment of FIG. 2, installation efficienciesmay not require large blocks of solar modules distributed over largeland areas. As a result, loads may be dictated by expected local peaksthat are smaller in size. As a result of the reduced load required to beborne by each post, posts may penetrate the ground to a shallower depth.In some cases, additional supporting material (e.g., concrete) may notbe required to secure the post within the ground. In some cases, thisinstallation structure may allow for simpler, less expensive, and lessinvasive installation techniques, e.g., by (hydraulic) pushing orthreading as described herein.

FIG. 3 shows a conventional ground mount structure 300 for supportingsolar modules 302, in accordance with some embodiments. This is aconnected structure comprising a separate superstructure 304 andrelatively massive pillars 306. These pillars occur at a relatively lowfrequency (F), and each bears a relatively large fraction of the entireload. In some cases, they are sunk to a substantial depth (D) within theearth 308—and may be secured therein with additional materials (notshown) such as concrete.

Instead of relying on separate, distinct, and massive superstructurecomponents for structural stability, some embodiments of the presentdisclosure may utilize inter-connectedness between modules in order toprovide stability. FIG. 4A shows a perspective view of a ground mountsystem 400, in accordance with some embodiments. In some cases, manyposts 450 may support a row of solar modules 402. In some cases,rectangular solar modules comprising seventy-two cells are shown.Various embodiments may support solar modules of various types. At eachcorner, the solar modules may be secured by a clip 404 to a respectivepost.

FIG. 4B is an end view of the ground mount system of FIG. 4A, inaccordance with some embodiments. FIG. 4B shows the tilt angle 410provided by the ground mount, which orients the solar module to catchthe sun's rays. FIG. 4B shows that wind can infiltrate the open side ofthe row, creating wind loading forces, in accordance with someembodiments.

While the ground mount embodiments of FIGS. 4A and 4B show a single rowof modules supported at a same tilt angle, alternative embodiments mayfeature rows with different tilt angle orientations. For instance, FIG.5A shows a perspective view of a ground mount system 500, in accordancewith some embodiments. In some cases, adjacent rows sharing common posts502, may alternate in tilt angles to create a peaked structure. In somecases, solar modules 504 may be secured to posts by clips havingdifferent shapes. One type of clip may be an end clip 506 that ispresent on a side of a row having no adjacent row on one side. FIGS. 7Aand 7B depict examples of end clips, in accordance with someembodiments. FIG. 7A shows a perspective view of an end clip accordingto an embodiment. As shown, the end clip is symmetric on both ends ofmodule. The end clip captures bottom side of frame and top side offrame. FIG. 7B shows a perspective view of an end clip with two modulesattached, in accordance with some embodiments. The center protrusion 700may prevent the module sliding from laterally. According to anembodiment, the end clip may be fabricated from 1 mm sheet metal.Another type of clip may be a middle clip 508 that is present betweenadjacent rows. FIG. 74 illustrates an example of a middle clip. Themiddle clip may be used for solar modules that interface with a post ina middle region of the lateral sides of the module. In some cases, theclip may have an angular opening to accommodate multiple tilt angles,and to facilitate autonomous positioning or alignment of the clip and/orthe module. In some cases, the post may have a flat face and a cutoutsuch that the post flange can be bent in and clinched (dimpled) to themodule clip in the locations corresponding to the green dots. The moduleclip may be mounted with a rivet or a bolt, or clinched to the moduleframe at its standard mounting points on the bottom flange. Another typeof clip may be a corner clip. FIGS. 8A-8C depict examples of cornerclips. FIG. 8A shows a perspective view of a corner clip 801 connectedto a frame 802 of a solar module 804 that comprises photovoltaicmaterial 806 (e.g., a plurality of solar cells). The clip may comprise acenter tab 800. FIG. 8B shows a perspective view of the corner clipconnected to two modules and a post, in accordance with someembodiments. The center tab 800 that mates (e.g., by clinching) with theface of the post tab, may be long enough to handle tolerances andimparts flexibility to accommodate tolerances in at least the rowdirection. FIG. 8C shows a perspective view of a pair of corner clipsand attached modules, connected to a post, in accordance with someembodiments. In some cases, the clips may exhibit a single, mirroreddesign such that the tabs land on opposite sides of the post. The cornerclips shown and described herein may not or need not require the use ofa fastener to clip on to a module.

FIG. 5B shows is a simplified end view of the embodiment of FIG. 5Ashowing loading forces. In some cases, the inability of wind to flowunderneath the raised side of the module rows, can substantially reducewind loading forces to which the ground mount system is expected to beexposed.

FIG. 6A is a perspective of a solar module array resulting from a groundmount system according to an embodiment. In some cases, the array maycomprise a plurality of short (two module) rows, separated by a smallspacing S. In some cases, many rows may be spaced closely together,conserving land area and increasing installation efficiency.

FIG. 6B is a perspective view of another solar module array resultingfrom a ground mount system according to an embodiment. In some cases,the array may comprise longer rows of modules. In some cases, thecorners of each row may be adjacent to the corners of the next row, andsupported by the same post.

While FIGS. 6A and 6B show solar arrays having rows oflandscape-oriented solar modules with long ends aligned in the rowdirection, this is not required. FIG. 6C shows a perspective view of analternative embodiment with portrait-oriented solar modules having theirshort ends aligned in the row direction.

FIG. 9 illustrates peel and shear forces to which the ground mountsystem may be subjected. Particular embodiments may provide at leastabout 400 lbs shear strength, and/or at least about 200 lbs of peelstrength.

FIG. 10 shows main tolerances of concern for a solar array installation,in accordance with some embodiments. In some cases, spacing betweenposts and/or angles of solar modules may be adjusted along a row, suchthat the solar array can be positioned or aligned in a desiredorientation. FIG. 10 also shows a tilt axis angular alignment, inaccordance with some embodiments. In some cases, the angular orientationof the solar modules may be fixed or movable. In some cases, the solarmodules may have a dual tilt angle. FIG. 10 further shows ground mountinstallation on a slope, in accordance with some embodiments. In somecases, a tracker may adjust an angle of a solar module from at leastabout 1° to about 10° or more in addition to the angle of the slope.

FIG. 10B shows a side perspective view indicating the impact of uneventerrain upon installation, in accordance with some embodiments. FIG. 10Cis an enlarged view showing the ability of the components of someembodiments disclosed herein, which may rotate relative to each other inorder to accommodate tolerances.

While some embodiments have shown a post with the ground end having asawtooth pattern, this is not required. Alternative embodiments mayutilize posts in the form of ground screws. In some embodiments, thepost may comprise two sections, with a screw portion going in first, anda top portion (allowing vertical adjustment) attached to the screwportion.

FIG. 10D shows a perspective view of an alternative embodiment featuringa ground screw. In some cases, a four way clip can be retained bystandard retaining rings that snap into grooves on the post. In somecases, the vertical tolerances can be accommodated by having multiplegrooves. In some cases, angular tolerances can be accommodated byoversizing the hole. In some cases, a component can withstand at leastabout 10 lbs, 20 lbs, 30 lbs, 40 lbs, 50 lbs, 100 lbs, 200 lbs, 300 lbs,400 lbs, 500 lbs, or more of uplift at a corner area.

FIG. 10A shows a perspective view where a clip that has been clinched inplace onto a post tab (e.g., using a tool of an installation machine),has rotated substantially to accommodate tolerances. In some cases,clinching may be performed in situ (e.g., when the module makes contactwith the post tab), which may lock in the position of the solar modulewhile accommodating for some additional flexibility. According to someembodiments, a clinching tool may perform at least 2 punches (e.g., 800lbs shear/400 lbs peel) for the full joint.

FIG. 14 is a simplified perspective view showing an embodiment of aclip/module assembly, adjacent to an alternative embodiment of a post.The post 1400 may comprise two opposing large tabs 1402 and 1404 at thetop, which provide large faces for the clips to be clinched against.FIG. 15 is a simplified view showing a clinching tool 1500 that can beused to clinch together the clip to a face of the post, in accordancewith some embodiments. FIG. 15A shows a simplified view of a resultingclinching joint, in accordance with some embodiments. FIG. 15B shows aview of a post according to an alternative embodiment. With two largetabs at the top, faces of large areas may be provided to clinch with theclips. FIG. 15C shows fabricated posts maintained in a bandolieredstructure after progressive stamping, in accordance with someembodiments.

The clips and clinching operations disclosed herein may permit theforming of a joint from two or more plates that overlap at leastpartially. The plates may not or need not be parallel to each other, andin fact can be angled relative to each other (e.g., depending on theterrain or the spatial configuration of other components associated withthe solar modules or the supporting structures for such modules). Theplates may be provided in different positions or orientations relativeto each other, and can be deformed uniquely to accommodate a wide rangeof angular or positional variations for the plates, the posts, thesurrounding terrain, or the positioning of any solar modules relative tothe plates or the posts. The presently disclosed systems and methods maypermit wide tolerances in the way that a joint is shaped or formed, tosimplify the installation process and provide additional flexibility inhow various components or systems are assembled relative to each other,without comprising structural integrity. The wide tolerances may alsopermit the installation of posts and solar modules without the need toprecisely fine tune the positions, the orientations, and/or the relativealignment of the posts or solar modules, especially when said posts orsolar modules are installed on uneven terrain with changing contours.

FIG. 16 is a simplified view showing a corner of four modules that jointo one post, in accordance with some embodiments. This view illustratesthe reversibility of the clips, and also demonstrates the angulartolerance of the clips relative to the post to accommodate tilt angle.

FIG. 17 shows a progressive stamping manufacturing process that can beused to fabricate the clip, in accordance with some embodiments. FIG. 18shows how the clip can maintain its connected orientation in anintegrated bandolier configuration after it is formed, in accordancewith some embodiments.

FIG. 19 shows another alternative embodiment of a ground mounting systemfor solar modules. In some cases, in the event of heavy loadingadditional clip(s) can be installed on the ridge of two modules (opensquare) and/or the lower confluence point of point of modules (solidsquare). These additional clips may connect two neighboring modules.Such additional-clip configurations may (but are not required to) alsoinclude a post (dashed) that can be pushed into the ground.

According to some embodiments, the clip may be pre-installed on a postin the factory. The retaining rings described herein may be installed inthe factory ahead of time. This may leave enough vertical tolerance forpenetration variability of the post. In some embodiments, this canpermit around 1 inch of vertical play, thereby facilitating installationand adding flexibility under applied loads.

FIG. 11 shows an enlarged perspective view of the gaps between adjacentmodules, in accordance with some embodiments. In some cases, the gapsmay be sized according to tolerance availability and to allow toolaccess. Particular embodiments may feature gaps of around 2″ on one sideof the module, with gaps on the orthogonal side of the module beingsmaller.

While the preceding figures have illustrated one particular embodimentof a ground mount system for solar panels, other embodiments arepossible. For example, FIG. 12 shows a simplified view of an alternativeclip structure 1200, in accordance with some embodiments. Here, the clipmay comprise flexible tabs 1202, and may be reversible. FIG. 13 is asimplified view showing the clip embodiment of FIG. 12 , attached to theside of a frame 1300 of a solar module 1302. In some cases, the clip maybe configured to engage on both the top and bottom of the module viamultiple tabs.

FIG. 42 shows an overhead view of an autonomous system for positioningand assembling solar modules, in accordance with some embodiments. Insome cases, the system may be configured to unbox, inspect, and/orprocess the solar modules with or without attachments beforetransporting around a site.

In some cases, the system may comprise one or more post installers. Thepost installers may drive posts and continuously reload from factorbundled packs. In some cases, posts may be installed by a custom machineon the back of a vehicle (e.g., a tractor). The vehicle may comprise anautonomous or semi-autonomous vehicle.

In some cases, the system may comprise one or more module installers.The module installers may pull a solar module from a stack and attachthem to one or more deployed posts. In some cases, a module may beinstalled on a previously installed post by a machine on the back of adifferent vehicle (e.g., a different tractor). The vehicle may comprisean autonomous or semi-autonomous vehicle.

FIG. 43 shows an overhead view of an autonomous system for positioningand assembling solar modules, in accordance with some embodiments. Insome cases, the vehicles for deploying posts or solar modules may befully electric. In some cases, a mobile power unit may be disposed at ornear a site where the vehicles may charge. In some cases, the mobilepower unit may be comprise one or more solar panels and/or batteries. Insome cases, a reloading unit may travel between stations. In some cases,a reloading unit may carry posts, solar modules, or any combinationthereof. In some cases, a reloading unit may travel between a prepstation and active installer units (e.g., the autonomous vehicles orrobots described elsewhere herein).

In another aspect, the present disclosure provides a method comprisingproviding one or more mobile platforms that are configured to carry aplurality of posts and a plurality of solar modules. The mobileplatforms may comprise any of the robots, machines, or autonomousvehicles described herein.

In some embodiments, a plurality of posts may be positioned andinstalled by a first mobile platform at a predefined configuration ontothe terrain. In some embodiments, a plurality of solar modules may bedeployed onto a set of posts by a second mobile platform.

In some cases, the one or more mobile platforms can be equipped with oneor more sensors. The one or more sensors may comprise, for example, alocation sensor (e.g., a geolocation sensor), a vision sensor (e.g.,image sensor or a camera), a GNSS unit, a GPS unit, an accelerometer, amotion sensor, a gyroscope, or any combination thereof. In some cases,the one or more sensors may comprise a stereo vision sensor, a depthsensor, a binocular vision sensor, or an infrared sensor. In some cases,the one or more sensors may comprise a radar unit, a LIDAR unit, analtitude sensor, a proximity sensor, an inertial measurement unit, acontact sensor, a pressure sensor, a piezoelectric sensor, or a forcesensor.

In some embodiments, the method may further comprise using at least theone or more sensors to (i) autonomously move the one or more mobileplatforms and (ii) autonomously position and assemble the plurality ofposts and the plurality of solar modules over a terrain to construct anarray of solar modules. In some embodiments, the method may furthercomprise using the one or more sensors to locate and move an installerload head on the one or more mobile platforms relative to the array ofsolar modules as the array is being constructed. The installer load headmay comprise a movable element that can automatically position and/ordeploy one or more posts into a target location.

In some embodiments, the one or more mobile platforms may comprise afirst platform for positioning and installing the plurality of postsonto the terrain, and a second platform for positioning and assemblingthe plurality of solar modules onto the plurality of posts. In someembodiments, the first platform can be separate from the secondplatform. In some embodiments, the first platform and the secondplatform may be integrated into a single platform. In some embodiments,the one or more mobile platforms may comprise one or more electricvehicles.

In some embodiments, the plurality of solar modules may be pre-stackedon the second platform, and the second platform may comprise a mechanismfor extracting a select solar module from the stack and assembling theselect solar module onto a select set of posts that have been installedon the terrain.

FIGS. 44A-44M show vehicles for positioning and assembling solarmodules, in accordance with some embodiments. In some cases, a moduleinstaller may be a custom machine built on a vehicle. In some cases, amodule installer may take in a stack of solar modules. In some cases,the stack of solar modules may be placed on the module installer. Insome cases, the stack of solar modules may be picked up by the moduleinstaller. In some cases, the module installer may carry the stack ofmodules. In some case, the module installer may separate one module fromthe stack of modules. In some cases, the module installer may positionthe one module over a plurality of installed posts, for example, two,three, or four installed posts. In some cases, the module installer maylower the module into a predetermined position over the plurality ofinstalled posts.

In some cases, the module installer may deform a metallic portion of amodule to create a rigid connection between the module and the post. Insome cases, the module installer may release the module. In some cases,the module installer may test a strength of connections formed betweenthe module and the plurality of posts by lifting, pushing, twisting, orany sufficient force.

In some cases, the module installer may drive to a next location toplace a module. In some cases, a module installer may comprise 3, 4, 5,or 6 degrees of motion or more. In some cases, a module installer maycomprise a robot arm that is configured to receive a module from aflipping machine. In some cases, a robot arm may be used to reach forand pick up a module from a stack. In some cases, a gantry may be usedto tilt back and forth to pick up a module and position the modulebehind. In some cases, a double rotary motion manipulator comprising oneor more rotating joints may be used to position a module above one ormore posts. In some cases, a gantry may be used to pick up and positionone or more modules onto one or more installed posts.

In some embodiments, an integrated clinching tool may be provided on aninstaller load head to create a plurality of post-clip interfacesbetween a plurality of clips and the plurality of posts. In some cases,the plurality of clips may be pre-attached to the plurality of solarmodules.

FIG. 53 illustrates a plurality of brackets that can be coupled to apost, in accordance with some embodiments. In some cases, a solar modulemay comprise a bracket. The bracket may be attached or coupled to thesolar module. In some cases, the bracket may comprise a deformablemetal. The deformable metal may comprise, for example, aluminum, copper,iron, steel, brass, or any metallic alloys. In some cases, a connectionmay be formed between the bracket and a post. In some cases, theconnection may be formed by clinching the bracket and the post together.In some cases, the bracket may comprise a flat or an angled piece ofmetal that is configured to rivet onto a module, for example, throughmounting holes. In some cases, the bracket may be connected to a moduleby clinching the bracket to the frame of a module. In one alternativeembodiment, the module clip can be clinched or dimpled to the solarmodule frame directly instead of being riveted or bolted throughmounting holes.

FIG. 51 illustrates a method for coupling a solar module and brackets,in accordance with some embodiments. In some cases, a bracket may beinstalled by a process in a station where modules are unboxed,inspected, and/or then placed on a tooling jig. In some cases, 1, 2, 3,4, or more rivet guns may install rivets to join a bracket to a solarmodule from below, side, top, or any sufficient direction. The use ofrivets may obviate the need for preformed holes with accuratetolerances. In some cases, a clinching tool or an impact driver (e.g.,for torquing nuts) may be used instead of a rivet gun.

In some embodiments, the method may further comprise assessing astructural integrity of the post-clip interfaces using at least one of ameasured force or a deflection during and/or after installation of thesolar modules onto the posts. In some cases, the structural integrity ofthe post-clip interfaces may be assessed by testing separation force,resistance to shear forces due to translational or rotational motions,and/or resistance to pull forces.

In some embodiments, the method may further comprise obtaining images ofthe plurality of post-clip interfaces during or after the interfaceshave been formed. In some embodiments, the method may further comprisedetermining a structural integrity of each of the plurality of post-clipinterfaces based at least on one or more of the images.

In some embodiments, the method may further comprise using a testingtool located on the one or more mobile platforms to perform pullstrength and assembly tests on one or more of the plurality of installedposts. In some cases, the testing tool may be used to apply pushing,pulling, twisting, vibration, or any appropriate force to an installedpost and/or an installed solar module to test the mechanical strength,stability, and/or rigidity of an installation.

In some cases, the method may further comprise using a testing toollocated on the one or more mobile platforms to perform electricaltesting on one or more solar modules. In some cases, the electricaltesting may comprise testing a voltage, current, connectivity, and anyappropriate electrical measurements to ensure proper installation of thesolar modules.

In another aspect, the present disclosure provides a method forconstructing an array of solar modules. The method may compriseproviding a plurality of posts and a plurality of solar modules. In somecases, the plurality of solar modules may comprise a plurality of clipspre-attached thereon. In some embodiments, the method may comprise usingone or more mobile platforms to autonomously position and assemble theplurality of posts and the plurality of solar modules over the terrainto construct the array of solar modules.

In some embodiments, the method may comprise forming a plurality ofpost-clip interfaces between a plurality of clips and the plurality ofposts to construct an array of solar modules over a terrain withoutrequiring one or more premade holes/features for one or more fasteners.In some embodiments, the plurality of post-clip interfaces may havetolerances that enable the array to contour to the terrain, therebyeliminating a need for grading of the terrain. In some embodiments, theplurality of post-clip interfaces may comprise a plurality of clinchedjoints. In some embodiments, the plurality of clinched joints can beformed by a dimpling process. In some embodiments, each of the pluralityof posts may comprise one or more tabs. In some cases, the dimplingprocess may comprise joining the one or more tabs to a correspondingclip to form the plurality of clinched joints. In some embodiments, themethod may further comprise adding the one or more fasteners to thepost-clip interfaces after or during the dimpling process.

In some cases, the plurality of post-clip interfaces can be formed atone or more corners of the plurality of solar modules. In some cases,the plurality of post-clip interfaces can be formed at all corners ofthe plurality of solar modules. In some cases, the plurality ofpost-clip interfaces can be formed at opposite corners of the pluralityof solar modules. In some cases, the plurality of post-clip interfacescan be formed at one or more lateral sides of the plurality of solarmodules. In some cases, the plurality of post-clip interfaces can beformed at all lateral sides of the plurality of solar modules. In somecases, the plurality of post-clip interfaces can be formed at oppositelateral sides of the plurality of solar modules.

In some cases, the plurality of post-clip interfaces can be formed byusing a clinching tool that is located on a post installer load head. Insome cases, the post installer load head may be located on one or moremobile platforms that are configured to carry the plurality of posts andthe plurality of solar modules.

In some embodiments, the plurality of post-clip interfaces can be formedwithout requiring the one or more fasteners. In some embodiments, theplurality of post-clip interfaces can be formed by locating the one ormore fasteners in position relative to each clip and a corresponding tabon each post, and piercing the one or more fasteners through the tab tofasten the tab onto the clip, or piercing the one or more fastenersthrough the clip to fasten the clip onto the tab.

In some embodiments, the presently disclosed methods may comprise usinga movable tool to form a plurality of holes in-situ on at least theclips on the solar modules and/or tabs on the posts. In someembodiments, the presently disclosed method may comprise using themovable tool or another tool to install the one or more fastenersthrough the plurality of holes formed in-situ on the clips and/or tabs.

In another aspect, the present disclosure provides an algorithm forfacilitating the deployment of a solar module. In some embodiments, themethod may comprise using an algorithm to identify a location suitablefor autonomous positioning and assembly of at least one solar module,without requiring aid or involvement from a user in the autonomouspositioning and assembly of the at least one solar module.

In some embodiments, the algorithm comprises a machine learning (ML)algorithm. In some cases, the machine learning algorithm may comprise aneural network. Examples of neural networks can include, for instance, adeep neural network (DNN), a convolutional neural network (CNN), arecurrent neural network (RNN), and/or a generative adversarial network(GAN).

In some embodiments, the machine learning algorithm may comprise a deepneural network (DNN). In other embodiments, the deep neural network maycomprise a convolutional neural network (CNN). The CNN may be, forexample, U-Net, ImageNet, LeNet-5, AlexNet, ZFNet, GoogleNet, VGGNet,ResNet18, or ResNet, etc. In some cases, the neural network may compriseor utilize, for example, a deep feed forward neural network, a recurrentneural network (RNN), LSTM (Long Short Term Memory), GRUs (GatedRecurrent Units), autoencoders (e.g., variational autoencoders,adversarial autoencoders, denoising autoencoders, or sparseautoencoders), a Boltzmann machine (BM), a RBM (Restricted BM), a deepbelief network, a generative adversarial network (GAN), a deep residualnetwork, a capsule network, or one or more attention/transformernetworks. In some embodiments, the neural network may comprise aplurality of neural network layers. In some cases, the neural networkmay have at least about 2 to 1000 or more neural network layers.

In some cases, the machine learning algorithm may comprise a supportvector machine (SVM), a classification algorithm, a regression analysisalgorithm, or any other type of supervised, semi-supervised, orunsupervised machine learning algorithm. In some embodiments, thesupervised learning algorithm may comprise or utilize, for example,support vector machine algorithms, linear regression algorithms,logistic regression algorithms, linear discriminant analysis algorithms,k-nearest neighbor algorithms, similarity learning, or any combinationthereof. In some embodiments, the unsupervised learning algorithm maycomprise, for example, clustering algorithms, hierarchical clusteringalgorithms, k-means clustering algorithms, mixture models, anomalydetection, local outlier factor algorithms, autoencoders, deep beliefnetworks, Hebbian learning, self-organizing maps,expectation—maximization algorithms (EM), principal component analysisalgorithms, independent component analysis algorithms, non-negativematrix factorization, singular value decomposition, or any combinationthereof. In some cases, the machine learning algorithm may comprise orutilize a random forest, a decision tree (e.g., a boosted decisiontree), a classification tree, a regression tree, a bagging tree, or arotation forest.

In some embodiments, the algorithm may be configured to identify thelocation for deploying one or more solar modules and/or posts based atleast on an analysis of terrain data. In some embodiments, the terraindata is obtained using at least one of aerial imaging or Globalnavigation satellite systems (GNSS).

In some embodiments, the method may further comprise creating a set ofexecutable instructions in a digital medium for an autonomous system toautonomously position, deploy, install, and/or assemble the at least onesolar module to construct a solar module array. In some embodiments, theautonomous system comprises a plurality of field machines that are inoperative communication via a network. In some embodiments, theplurality of field machines comprise one or more robots. In someembodiments, the method may further comprise creating a set ofexecutable instructions in a digital medium for an autonomous system toautonomously position, deploy, install, and/or assemble one or moreposts or other supporting structures for one or more modules of a solarmodule array.

In another aspect, the present disclosure provides an apparatus that isconfigured to: carry a plurality of posts over a terrain; autonomouslyposition a select post from the plurality of posts at a predeterminedlocation on the terrain; and autonomously install the select post at thepredetermined location. In some cases, the select post and the pluralityof posts can be useable to support a plurality of solar modules.

FIGS. 45A-45D show perspective views of a machine for installing posts,in accordance with some embodiments. In some cases, the machine maycomprise 3, 4, 5, or 6 degrees of freedom or more. In some cases, themachine may autonomously position a post, install the post in theground, and/or force-test the post by pulling on it laterally,vertically, or any other direction and record the force-test data. Insome cases, the machine may be configured to carry one or more bundlesof posts on a rack. In some cases, the machine may be configured tolocate one or more posts in a bundle of posts and collect a new post ona driving bit.

FIGS. 46A-46B show a machine for installing posts, such as thoseillustrated in FIGS. 49A-49C. In some cases, the machine may have 3 ormore mounting interfaces to mount a tractor to, for example, using a 3point hitch. In some cases, the machine may carry a hammer for poundinga post into the ground. In some cases, the hammer may be mounted onvertical rails and may be free to slide vertically or in any othersufficient direction such that sufficiently small or no vibration istransferred from the hammer to the remainder of the machine.

FIGS. 50A-50C show coupling mechanisms between posts and a rack, inaccordance with some embodiments. In some cases, a post may comprise a Zshaped section or a Z shape. In some cases, a post may comprise a shapethat is substantially stackable. In some cases, a post may comprise oneor more oblique set of tabs at the top. In some cases, a tab maycomprise a cutout feature. In some cases, a cutout feature may beconfigured to allow a post to be hung from a hanger or a rack. In somecases, one or more posts may be bundled and shipped in a container orprovided to a machine.

In some embodiments, the apparatus may be further configured to performa force test after the select post has been installed at thepredetermined location. In some embodiments, the force test may compriseapplying a pull force on the select post in at least one of a lateraldirection or a vertical direction.

In some embodiments, the select post may be installed at a predeterminedlocation using a load driving mechanism configured to drive the selectpost into the ground at the predetermined location. In some cases, theload driving mechanism comprises or is coupled to a hammer. In somecases, the load driving mechanism is mounted to and movable along aplurality of rails in a vertical direction. In some cases, the loaddriving mechanism is configured to slide along the plurality of railsvia bearings.

In some cases, the load driving mechanism comprises a retentionmechanism that prevents the select post from displacing or decouplingfrom the load driving mechanism as the select post is being installedinto the ground. In some cases, the retention mechanism comprises one ormore shear features.

In some cases, the load driving mechanism comprises a driving bit havingone or more shear features. In some cases, the one or more shearfeatures may be configured to dually function as retention features. Insome cases, the load driving mechanism is configured to have a drivingforce length that is less than a full longitudinal length of the selectpost.

FIGS. 47A-47I show coupling mechanisms between a driving bit and a post,in accordance with some embodiments. In some cases, a driving bit may beconnected to a hammer. In some cases, a driving bit may comprise a shearinterface for engaging a post during the pounding. In some cases, adriving bit may comprise a retention feature which prevents a post fromfalling off of the bit while it is being positioned and driven. In somecases, a driving bit may be configured to allow a post to be poundedfrom the post's web, which may be disposed lower on the body of thepost. In some cases, pounding from the web may allow the hammer toimpact the post with greater force, as compared to impacting from thehead, because pounding from the web may effectively lower the bucklinglength of the post during pounding. In some cases, a driving bit mayenter a larger portion of a hole in a post. In some cases, a driving bitmay slide down in a configuration and retain against a chisel bit. Insome cases, a head of a chisel feature on a driving bit may overlap withat least a portion of a post when the driving bit is engaged with thepost. In some cases, there may be 1, 2, 3, 4, or more shear features ona chisel bit. In some cases, a chisel bit may also be used as aretention feature. In some cases, a feature on a chisel bit may retain apost. In some cases, a feature on a chisel bit may be separate from afeature that is pounding the post. In some cases, a retention featuremay be a clocking element that rotates to engage with a post. In somecases, a retention feature may be a clocking square that turns about 45degrees such that the corners retain a post once engage. In some cases,a retention feature may overhang a hole in the post. In some cases, ashaft may not engage a bottom of a hole in the post. In some cases, apin may engage with a post without overhanging. FIGS. 48A-48B show acomparison of driving a post using different coupling mechanisms, inaccordance with some embodiments.

In some embodiments, the post may be driven into a terrain using acomponent that is positioned, oriented, and/or moved to impact a featurethat is positioned along a length of the post. The component maycomprise a hammer, a pin, or any other rigid structural member. In somecases, the movement of the component may be guided using a sleeve or arail. The impact between the component and the feature may provide adriving force to push a post into a desired location. The point ofimpact may be closer to a center of gravity or a center of mass of thepost, which can help to minimize buckling forces and to ensure that thepost is installed in a desired orientation (e.g., perpendicular to theterrain or at any other desired angle relative to the terrain).

In another aspect, the present disclosure provides an apparatus that isconfigured to carry a plurality of solar modules over a terrain;autonomously position a select solar module from the plurality of solarmodules over a set of posts installed on the terrain; and autonomouslyassemble the select solar module to the set of posts without requiringor using fasteners.

In some cases, the apparatus may be configured to autonomously assemblethe select solar module to the set of posts by forming a plurality ofpost-clip interfaces. In some cases, the plurality of post-clipinterfaces comprise a plurality of clinched joints.

In some cases, the select solar module can be pre-attached with a clipat one or more corners or sides of the select solar module, and eachpost in the set of posts may comprise a plurality of tabs. In somecases, the apparatus may be configured to autonomously position theselect solar module over the set of posts by aligning the clip to acorresponding tab at each post. In some cases, the apparatus may beconfigured to autonomously assemble the select solar module to the setof posts by clinching the corresponding tab to the clip at each post.

FIG. 59 illustrates a light curtain, in accordance with someembodiments. In some cases, a machine may comprise one or more opticalsensors configured to detect when a foreign object (e.g., a human oranother agent) enters a workspace defined by a light curtain. When aforeign object enters the workspace, at least a portion of the lightcurtain may be interrupted or disrupted, which can trigger one or moresafety procedures or protocols (e.g., shutting down a machine orlimiting an operation of the machine until the foreign object exits theworkspace).

The following examples are provided to further illustrate someembodiments of the present disclosure, but are not intended to limit thescope of the disclosure; it will be understood by their exemplary naturethat other procedures, methodologies, or techniques known to thoseskilled in the art may alternatively be used.

FIG. 20 shows a layout of blocks of solar modules in a connectedorientation. FIG. 21 shows a plurality of blocks connected to a centralinverter.

FIG. 22 is a perspective view of a portion of a block. The lines 2200here show how the wires going from the module strings to the inverter(the ‘home runs’), can be mounted on the side of an array and clipped tothe posts.

FIG. 23 is a simplified flow diagram illustrating a supply chain that ismade available according to embodiments. The simplicity of this supplychain allows the posts, joints, and prefabricated solar modules to beshipped from the factories to a location for deployment. There, thesecomponents can be installed onto a machine that is configured for rapidand automatic installation of the ground mount system.

FIG. 24 is a simplified overhead view showing progress of one embodimentof an installation machine 2400 over a site. Here, the machine is towedby a truck 2402, in a right-to-left direction. After the posts arepushed into the ground, the modules can be attached. In this particularembodiment, the modules may have clips pre-installed in them.

FIG. 25 is a simplified overhead view showing progress of an alternativeembodiment of an installation machine 2500 over a site, fromleft-to-right. This particular embodiment utilizes a post tool jig 2502that comprises a rectangle of fixed dimensions, in order to always indexthe next pair of posts 2504 off of the previous pair. Specifically, in afirst phase 2505 two posts are pushed into the ground, with the jig usedto position the posts relative to one another. In a second phase 2506,two more posts are pushed into the ground, again with the jig used toposition the posts. In a third phase 2508, the module 2509 is placeddirectly after next pair of posts. The jig can grab features on clips onposts to both index and to hold the clips while pressing modules intothem. A fourth phase 2510 places the next posts (e.g., using the jig toindex from previous posts). The process may then be repeated.

In some cases, the path of the installation machine may be serpentineover the site. When the vehicle turns around and does the other side ofthe row (from right-to-left), everything is the same except only postsclosest to the truck are implanted. The two specific installationmachines presented in FIG. 24 and FIG. 25 are examples only, andalternative embodiments may be used.

FIG. 26 provides a formal coordinate system for describing a movingvehicle. This coordinate system is now referenced to describe anotherexemplary embodiment of an apparatus configured to perform installationof ground mounted solar panels.

FIG. 27 shows a rear perspective view of one embodiment 2700 of theinstallation apparatus. The apparatus comprises various elements mountedto a moving vehicle 2702 (e.g., a pickup truck bed)—via a platform 2704.As described in detail below, this platform may be configured to move inone or more direction(s). Elements of the installation machinery maycomprise a frame 2706 and a load head 2708. A vertical conveyor 2710 maybe configured to receive a stack 2712 of individual pre-fabricated solarpanels 2714. In some cases, the installation machinery may furthercomprise a hydraulic actuator 2716 for implanting posts into the groundby pushing (rather than hammering).

FIG. 28 shows a detail of the vertical conveyor element which can beused to lower modules one at a time. FIG. 29 is a schematic view showinghow standard packaging of a stack 2900 of solar modules, can be loadedon to vertical conveyors 2904 and individual modules 2904 then loweredonto the sheet metal clips 2906. The modules can be lowered onto thesheet metal clips 2906. The resultant combination of the module andclips can be lowered onto a tray 2910, which can slide out from thebottom of this stack.

FIG. 30 shows a detail of a module including a frame 3000 that is beinglowered onto a clip 3002. The joint's connection 3003 to its adjacentjoint can be severed by the piece 3004 during this process.

FIG. 31 shows a side view of a stack 3100 of solar modules on a verticalconveyor 3104. A horizontal rail 3106 can be used to slide the bottommodule laterally onto the installation load head 3108. The module can betilted by a small linear actuator 3110.

FIG. 32 shows a front perspective view of the installation apparatusaccording to an embodiment. The load head 3200 is shown in verticalsliding motion relative to the frame 3204 which is connected to thetruck 3206. This motion can be actuated by a hydraulic actuator 3208which is mounted to the frame.

FIG. 33 shows a detailed view of the load head frame 3300 connected tothe actuator tip 3302 that is used to (simultaneously) drive in the post3304. A joint 3306 can be seen already attached to the solar module 3308that is loaded into the load head. The tip 3308 of the actuator that ispushing directly on the post is also connected to the module load head.Thus, the module can be lowered into the correct place simultaneously asthe post is driven into the ground. The connection between the actuatortip and the module load head can also have a flexure to reducevibrations from being transferred to the module during installation.

In connection with the installation machine embodiment of FIGS. 27-33 ,one or more of the various elements (e.g., frame, load head,conveyor(s), others) can be mounted on the movable platform. Thatplatform can be actuated in either: (i) x-axis, y axis, and yawdirections, or (ii) x-axis, y axis, yaw, pitch, and roll directions.

In some cases, a vertical actuator can control the Z axis motion. Onemethod of controlling planar motion is via a two-way table. Anadditional drive can control the yaw direction.

FIG. 34 further shows that the position of the moveable platform may becontrolled (either separately or individually) by the use of: (i) adifferential GPS system, (ii) cameras, (iii) lidar, and/or (iv) lasertracking. In some cases, a GPS and/or camera system may allow controlover how to precisely place each module and post in the solar array.This functionality can provide control over the movable machinery on thered platform, and/or the position/driving of the entire installationapparatus (e.g., as disposed in a truck, within a trailer, or in theform of a specially-built vehicle).

Embodiments are not limited to the specific installation apparatusesdescribed above, and alternatives are possible. For example, FIG. 35shows a front perspective view of an alternative embodiment of aninstallation machine.

FIG. 36 shows an enlarged side view of the installation apparatus 3600illustrated in FIG. 35 . Here, the load head 3601 can slide inside aretained fixture 3602 to install a single solar module 3604 in avertical linear motion. The load head may be captured inside of therigid frame to constrain motion to only vertical (shown by the arrow3606).

FIG. 34 shows one non-limiting example of a platform that can be used tofacilitate solar module deployment and installation. In someembodiments, the position of the module and load head can be controlledusing a mechanism such as the overhead part 3700 shown in FIG. 37A,which can be attached to a frame of the platform.

FIG. 37B shows the overhead part as taking the form of a gantry 3704 tocontrol planar positioning. FIG. 37C shows an enlarged view of arotational gear 3702 that may be mounted below. In some cases, othermechanisms such as a conveyor (e.g., a vertical conveyor or a horizontalconveyor) may be used to control positioning of the modules.

FIG. 38A shows a perspective view of an embodiment where modules arelifted off of their stack on a pallet by a gantry with a suction cupload head and translated over and put down onto the module slider (shownextended in FIG. 31 ). This gantry can press the modules down onto thefour clips during the motion #3 shown in FIG. 38B to install the clipsonto the module.

FIG. 39 shows an overhead view of an embodiment comprising a dual tilt(between 0 and 20 degrees) array 3900 of ground mounted solar modules.This uninterrupted array of modules may provide a valuable opportunityto clean the array using a robot 3902. This cleaning robot canautonomously travel in any direction on the module plane.

FIG. 40 shows an overhead view of another alternative embodiment. Here,the array of solar modules may be installed with a stagger between therows of modules. Such an implementation may add significant stiffness inthe stagger direction due to the overlapping frames. Apart fromconsuming 50% more posts, such an embodiment could function in a mannersimilar to those described previously.

In the configuration where the modules are staggered, there may be 6posts per module, and the clip can be modified to clamp on the corner oftwo modules and the middle edge of a third module. In FIG. 41 , postlocations are shown as a white square at the intersection of a moduleedge and two corners of adjacent modules.

FIGS. 54A-54C illustrate a method for determining a landscape topologyfor positioning and assembling solar modules, in accordance with someembodiments. In some cases, the method may comprise analyzing a terraintopology and/or GIS data of a given terrain. In some cases, the methodmay comprise processing a curvature of the terrain topology or GIS data.In some cases, the method may comprise simulating posts and modulesinstalled on the given terrain. In some cases, the method may compriseuploading the posts and the modules geolocation position andconstruction data for one or more machines for installing the posts andthe modules. FIG. 55 illustrates an exemplary GUI for determining alandscape topology for positioning and assembling solar modules, inaccordance with some embodiments.

In some cases, one or more algorithms, machine learning algorithms, orneural networks may be configured to process data of a terrain anddetermine an optimal layout, positioning, or installation location forone or more posts or solar modules. In some cases, the one or morealgorithms, machine learning algorithms, or neural networks may beimplemented to generate a virtual representation or simulation of aterrain and one or more candidate locations for installing posts orsolar modules. In some cases, the one or more algorithms, machinelearning algorithms, or neural networks may be configured to generate ablueprint or a set of instructions for controlling and moving aplurality of robots or mobile platforms to collectively deploy andinstall one or more posts or solar modules in a target environment. Suchblueprint or set of instructions may be generated based on the virtualrepresentation or simulation, or other data associated with the terrainor the landscape topology of the target environment. The virtualrepresentation or simulation may comprise, for example, a 3D model or apoint cloud representation of the terrain and the one or more candidateinstallation or deployment locations.

In some embodiments, when the robots or mobile platforms of the presentdisclosure run out of posts or solar modules for installation (or if thenumber of posts or solar modules immediately accessible to the robots ormobile platforms drops below a certain threshold), the robots or mobileplatforms may undergo a restocking or replenishment operation. In somecases, the robots or mobile platforms may return to a facility or othercentral location for restocking or replenishing of posts and/or solarmodules. In other cases, one or more other restocking vehicles or robotsmay carry or store an inventory of additional posts and/or solarmodules, and can automatically travel to a robot or mobile platform thatneeds additional posts or solar modules. In some cases, the one or moreother restocking vehicles or robots may travel or idle along a perimeterof the terrain, and travel to a particular robot or mobile platform whenthe robot or mobile platform requires additional posts or solar modules.This can avoid the need for the robot or mobile platforms to make anadditional trip for restocking or replenishment purposes.

FIG. 62 illustrates an alternative embodiment of an exemplary vehiclethat can be used or configured to handle, transport, install, or deployone or more solar modules. The vehicle may acquire new stacks of modulesautonomously, semi-autonomously, or with aid of human input orintervention. The vehicle may not or need not use or rely on a separaterobot to acquire new stacks of modules. In some cases, the vehicle maycomprise one or more front attachments that can be used to retrieve orobtain new solar modules from a stocking area or another vehicle.

FIG. 63 illustrates another alternative embodiment of an exemplaryvehicle that can be used or configured to handle, transport, install, ordeploy one or more solar modules. In some embodiments, the vehicle maybe configured to use a robot to move new solar modules off of a trailerof another vehicle.

FIG. 64 illustrates an end-effector with clinch tools positioned at thecorners of the end-effector. The end-effector in this case may not orneed not use suction cups to pick up a solar module, and can insteadgrab the modules from the side by a squeezing or pinching action. Thesize of the frame of the end-effector may be adjustable such that thesame end-effector can be configured to pick up modules of differentshapes or sizes. As shown in FIG. 65 , the bottom portion of the clinchtools can be tapered to help the clinch tools locate or engage with themodule (e.g., a complementary feature disposed on the module).

FIGS. 66A and 66B illustrate an alternate embodiment of a clip. The clipmay comprise a hole or a slot that can interface with a latch that turns90 degrees automatically which then engages the module and clip assemblywith the load head on the module installer thus holding it in place.This is another embodiment of a way to pick up a solar module withoutusing a suction cup.

FIG. 67 illustrates an alternative embodiment of a module installervehicle as described elsewhere herein. Here, the clinch tools (yellow)may not or need not be located on the same piece of automation that ismoving the module (orange) but can instead be located on a separatepiece of automation (blue) which is attached to the same mobile vehicleplatform as the automation that moves the modules. The separate piece ofautomation (blue) may autonomously and releasably mate to previouslyinstalled posts. The module-moving automation (orange) can then move amodule to the location where the posts are installed.

FIG. 68 illustrates an exemplary configuration for a post as describedelsewhere herein. This embodiment shows cutout flanges that are bent outin a flared way such that they allow the post to enter the soil with lowresistance (left), but then when the post is pulled up, they are engagedwith the soil and bend out more, providing increased uplift resistance(right).

FIGS. 69A and 69B illustrate an alternative embodiment of the clipsdescribed elsewhere herein. In this embodiment, the clips may have bendsand tabs such that they nest and stack so that the solar modules do notcontact the other modules above or below them in the stack.

FIG. 70A illustrates an additional sheet metal feature that can be usedto retain one or more lead wires or wire leads of a solar module andhold them fixed in a specific side of the module, for later handling orprocessing. FIG. 70B illustrates an embodiment of a clip where themodule wire lead is connected to the clip that is also connected to themodule and that will be connected to the post. FIG. 70C illustratesusing an additional tool (blue squares) to autonomously take the solarmodule wire leads that are held in place by the clip and connect them toeach other to form an electrical connection between the modules. FIG. 71illustrates an embodiment of the tool and method in FIGS. 70A, 70B, and70C, except in this embodiment, the tool does not push two connectorstogether, and instead it cuts (a), strips (a), and splices (b) the wirestogether in place without the use of a connector.

FIG. 75 illustrates a removable access trough that can be placed on topof posts in the valley or peaks of the module array. This trough cantransfer its weight and load to the posts below it and not to themodules, and can be walked on top of in order to access modules in theinterior regions of the array. In some cases, this trough can also be arail that a robot can ride on (e.g., to clean, water, spray, orinspect).

FIG. 76 and FIG. 77 illustrate a gantry (blue) on wheels (black) thatcan drive on the ground in the gaps between the array in certainconfigurations. This gantry can be outfitted with automation to cleanthe modules with water, or to mechanically wipe the solar modules in thearray beneath the gantry. This gantry can also spray water or herbicide,or hydroseed, to manage vegetation underneath the array. The gantry canhave a cord, a tube, or other hollow structure attached thereto toconnect it to a source of water or other liquids at the end of a row ofmodules.

Computer Systems

In an aspect, the present disclosure provides computer systems that areprogrammed or otherwise configured to implement methods of thedisclosure, e.g., any of the subject methods for using at least onerobot to fully autonomously position and assemble at least one solarmodule and its supporting structure.

In another aspect, the present disclosure provides computer systems thatare programmed or otherwise configured to provide one or more mobileplatforms that are configured to carry a plurality of posts and aplurality of solar modules. In some cases, the one or more mobileplatforms are equipped with one or more sensors comprising a geolocationsensor. In some cases, the computer systems are further programmed orotherwise configured to use at least in part the readings ormeasurements obtained using one or more sensors to (i) autonomously movethe one or more mobile platforms and (ii) autonomously position andassemble the plurality of posts and the plurality of solar modules overa terrain to construct an array of solar modules. Such autonomousmovement or positioning may be performed using one or more signals orcommands generated by a computing unit of the computer system.

In another aspect, the present disclosure provides computer systems thatare programmed or otherwise configured to provide a plurality of postsand a plurality of solar modules. In some cases, the plurality of solarmodules comprises a plurality of clips pre-attached thereon. In somecases, the computer systems are further programmed or otherwiseconfigured to form a plurality of post-clip interfaces between aplurality of clips and the plurality of posts to construct an array ofsolar modules over a terrain without requiring one or more premadeholes/features for one or more fasteners.

In another aspect, the present disclosure provides computer systems thatare programmed or otherwise configured to use an algorithm to identify alocation suitable for autonomous positioning and assembly of at leastone solar module. In some cases, using the algorithm may be performedwithout requiring aid or involvement from a user in the autonomouspositioning and assembly of the at least one solar module.

FIG. 61 shows a computer system 6101 that is programmed or otherwiseconfigured to implement a method for fully autonomously positioning andassembling at least one solar module and its supporting structure. Insome embodiments, the computer system 6101 may be configured to, forexample, use an algorithm to identify a location suitable for autonomouspositioning and assembly of at least one solar module, without requiringaid or involvement from a user in the autonomous positioning andassembly of the at least one solar module. The computer system 6101 canbe an electronic device of a user or a computer system that is remotelylocated with respect to the electronic device. The electronic device canbe a mobile electronic device.

The computer system 6101 may include a central processing unit (CPU,also “processor” and “computer processor” herein) 6105, which can be asingle core or multi core processor, or a plurality of processors forparallel processing. The computer system 6101 also includes memory ormemory location 6110 (e.g., random-access memory, read-only memory,flash memory), electronic storage unit 6115 (e.g., hard disk),communication interface 6120 (e.g., network adapter) for communicatingwith one or more other systems, and peripheral devices 6125, such ascache, other memory, data storage and/or electronic display adapters.The memory 6110, storage unit 6115, interface 6120 and peripheraldevices 6125 are in communication with the CPU 6105 through acommunication bus (solid lines), such as a motherboard. The storage unit6115 can be a data storage unit (or data repository) for storing data.The computer system 6101 can be operatively coupled to a computernetwork (“network”) 6130 with the aid of the communication interface6120. The network 6130 can be the Internet, an internet and/or extranet,or an intranet and/or extranet that is in communication with theInternet. The network 6130 in some cases is a telecommunication and/ordata network. The network 6130 can include one or more computer servers,which can enable distributed computing, such as cloud computing. Thenetwork 6130, in some cases with the aid of the computer system 6101,can implement a peer-to-peer network, which may enable devices coupledto the computer system 6101 to behave as a client or a server.

The CPU 6105 can execute a sequence of machine-readable instructions,which can be embodied in a program or software. The instructions may bestored in a memory location, such as the memory 6110. The instructionscan be directed to the CPU 6105, which can subsequently program orotherwise configure the CPU 6105 to implement methods of the presentdisclosure. Examples of operations performed by the CPU 6105 can includefetch, decode, execute, and writeback.

The CPU 6105 can be part of a circuit, such as an integrated circuit.One or more other components of the system 6101 can be included in thecircuit. In some cases, the circuit is an application specificintegrated circuit (ASIC).

The storage unit 6115 can store files, such as drivers, libraries andsaved programs. The storage unit 6115 can store user data, e.g., userpreferences and user programs. The computer system 6101 in some casescan include one or more additional data storage units that are locatedexternal to the computer system 6101 (e.g., on a remote server that isin communication with the computer system 6101 through an intranet orthe Internet).

The computer system 6101 can communicate with one or more remotecomputer systems through the network 6130. For instance, the computersystem 6101 can communicate with a remote computer system of a user(e.g., an end user or entity overseeing, supervising, monitoring, ormanaging an operation of the robots). Examples of remote computersystems include personal computers (e.g., portable PC), slate or tabletPC's (e.g., Apple® iPad, Samsung® Galaxy Tab), telephones, Smart phones(e.g., Apple® iPhone, Android-enabled device, Blackberry®), or personaldigital assistants. The user can access the computer system 6101 via thenetwork 6130.

Methods as described herein can be implemented by way of machine (e.g.,computer processor) executable code stored on an electronic storagelocation of the computer system 6101, such as, for example, on thememory 6110 or electronic storage unit 6115. The machine executable ormachine readable code can be provided in the form of software. Duringuse, the code can be executed by the processor 6105. In some cases, thecode can be retrieved from the storage unit 6115 and stored on thememory 6110 for ready access by the processor 6105. In some situations,the electronic storage unit 6115 can be precluded, andmachine-executable instructions are stored on memory 6110.

The code can be pre-compiled and configured for use with a machinehaving a processor adapted to execute the code, or can be compiledduring runtime. The code can be supplied in a programming language thatcan be selected to enable the code to execute in a pre-compiled oras-compiled fashion.

Aspects of the systems and methods provided herein, such as the computersystem 6101, can be embodied in programming. Various aspects of thetechnology may be thought of as “products” or “articles of manufacture”typically in the form of machine (or processor) executable code and/orassociated data that is carried on or embodied in a type of machinereadable medium. Machine-executable code can be stored on an electronicstorage unit, such as memory (e.g., read-only memory, random-accessmemory, flash memory) or a hard disk. “Storage” type media can includeany or all of the tangible memory of the computers, processors or thelike, or associated modules thereof, such as various semiconductormemories, tape drives, disk drives and the like, which may providenon-transitory storage at any time for the software programming. All orportions of the software may at times be communicated through theInternet or various other telecommunication networks. Suchcommunications, for example, may enable loading of the software from onecomputer or processor into another, for example, from a managementserver or host computer into the computer platform of an applicationserver. Thus, another type of media that may bear the software elementsincludes optical, electrical and electromagnetic waves, such as usedacross physical interfaces between local devices, through wired andoptical landline networks and over various air-links. The physicalelements that carry such waves, such as wired or wireless links, opticallinks or the like, also may be considered as media bearing the software.As used herein, unless restricted to non-transitory, tangible “storage”media, terms such as computer or machine “readable medium” refer to anymedium that participates in providing instructions to a processor forexecution.

Hence, a machine readable medium, such as computer-executable code, maytake many forms, including but not limited to, a tangible storagemedium, a carrier wave medium or physical transmission medium.Non-volatile storage media including, for example, optical or magneticdisks, or any storage devices in any computer(s) or the like, may beused to implement the databases, etc. shown in the drawings. Volatilestorage media include dynamic memory, such as main memory of such acomputer platform. Tangible transmission media include coaxial cables;copper wire and fiber optics, including the wires that comprise a buswithin a computer system. Carrier-wave transmission media may take theform of electric or electromagnetic signals, or acoustic or light wavessuch as those generated during radio frequency (RF) and infrared (IR)data communications. Common forms of computer-readable media thereforeinclude for example: a floppy disk, a flexible disk, hard disk, magnetictape, any other magnetic medium, a CD-ROM, DVD or DVD-ROM, any otheroptical medium, punch cards paper tape, any other physical storagemedium with patterns of holes, a RAM, a ROM, a PROM and EPROM, aFLASH-EPROM, any other memory chip or cartridge, a carrier wavetransporting data or instructions, cables or links transporting such acarrier wave, or any other medium from which a computer may readprogramming code and/or data. Many of these forms of computer readablemedia may be involved in carrying one or more sequences of one or moreinstructions to a processor for execution.

The computer system 6101 can include or be in communication with anelectronic display 6135 that comprises a user interface (UI) 6140 forproviding, for example, a portal for monitoring the installation ofposts or solar modules. In some cases, the UI may permit inputs such ascommands to “begin installation” or “halt all robots.” In some cases,the UI may provide a visualization or a blueprint for installingmultiple solar modules of a solar module array. In some cases, the UImay provide a visualization tracking one or more robots in real-time.The portal may be provided through an application programming interface(API). A user or entity can also interact with various elements in theportal via the UI. Examples of UI's include, without limitation, agraphical user interface (GUI) and web-based user interface.

Methods and systems of the present disclosure can be implemented by wayof one or more algorithms. An algorithm can be implemented by way ofsoftware upon execution by the central processing unit 6105. Forexample, the algorithm may be configured to determine one or morelocations for installing one or more solar modules. In some cases, thealgorithm may be configured to coordinate one or more robots duringinstallation of one or more solar modules. In some cases, the algorithmmay be configured to process force-testing data of one or more solarmodules to determine if the one or more solar modules are installedsecurely. In some cases, the algorithm may be configured to provideinstructions to the one or more robots to adjust the one or more solarmodules or supporting structures thereof based at least in part on theforce-testing data.

While preferred embodiments of the present invention have been shown anddescribed herein, it will be obvious to those skilled in the art thatsuch embodiments are provided by way of example only. It is not intendedthat the invention be limited by the specific examples provided withinthe specification. While the invention has been described with referenceto the aforementioned specification, the descriptions and illustrationsof the embodiments herein are not meant to be construed in a limitingsense. Numerous variations, changes, and substitutions will now occur tothose skilled in the art without departing from the invention.Furthermore, it shall be understood that all aspects of the inventionare not limited to the specific depictions, configurations or relativeproportions set forth herein which depend upon a variety of conditionsand variables. It should be understood that various alternatives to theembodiments of the invention described herein may be employed inpracticing the invention. It is therefore contemplated that theinvention shall also cover any such alternatives, modifications,variations or equivalents. It is intended that the following claimsdefine the scope of the invention and that methods and structures withinthe scope of these claims and their equivalents be covered thereby.

What is claimed is:
 1. A method for constructing an array of solarmodules, comprising: (a) providing one or more mobile platforms thatcarry a plurality of posts and a plurality of solar modules, wherein theone or more mobile platforms are equipped with one or more sensorscomprising a geolocation sensor; and (b) using at least the one or moresensors to (i) autonomously move the one or more mobile platforms and(ii) autonomously position and assemble at least one post of theplurality of posts and at least one solar module of the plurality ofsolar modules over a terrain, thereby constructing the array of solarmodules.
 2. The method of claim 1, wherein the array of solar modules isconstructed on a substantially non-flat terrain.
 3. The method of claim1, wherein the array of solar modules is constructed on a substantiallyflat terrain.
 4. The method of claim 1, wherein the array of solarmodules comprises a complete wired array or a dual-tilt array.
 5. Themethod of claim 1, further comprising: using an algorithm to identify alocation suitable for autonomous positioning and assembly of the atleast one solar module of the plurality of solar modules; and creating aset of executable software instructions for controlling the one or moremobile platforms to autonomously position and assemble the at least onepost of the plurality of posts and the at least one solar module of theplurality of solar modules over the terrain to construct the array ofsolar modules without requiring aid or involvement from a user.
 6. Themethod of claim 1, wherein the one or more sensors further comprise animage sensor.
 7. The method of claim 1, wherein the one or more mobileplatforms comprise (i) a first platform for positioning and installingthe at least one post of the plurality of posts onto the terrain and(ii) a second platform for positioning and assembling the at least onesolar module of the plurality of solar modules onto the at least onepost.
 8. The method of claim 7, wherein the plurality of solar modulesare provided on the second platform in a stack, and wherein the secondplatform comprises a mechanism for extracting the at least one solarmodule from the stack and assembling the at least one solar module ontoone or more posts that have been installed on the terrain.
 9. The methodof claim 1, further comprising: using the one or more sensors to locateand move an installer load head on the one or more mobile platforms asthe array of solar modulus is being constructed.
 10. The method of claim9, further comprising: creating a plurality of post-clip interfacesbetween a plurality of clips and the plurality of posts using at leastan integrated clinching tool on the installer load head, wherein theplurality of clips are pre-attached on the plurality of solar modules.11. The method of claim 10, wherein the plurality of post-clipinterfaces have tolerances that enable the array of solar modules tocontour to the terrain without use of a grading of the terrain.
 12. Themethod of claim 10, wherein the plurality of post-clip interfacescomprise a plurality of clinched joints.
 13. The method of claim 12,wherein the plurality of clinched joints are formed by a dimplingprocess.
 14. The method of claim 13, wherein a post of the plurality ofposts comprises one or more tabs, and wherein the dimpling processcomprises joining the one or more tabs to a corresponding clip to formthe plurality of clinched joints.
 15. The method of claim 10, whereinthe plurality of post-clip interfaces are formed by: a. locating one ormore fasteners in position relative to a clip of the plurality of clipsand a tab on a post of the plurality of posts, and b. piercing (i) theone or more fasteners through the tab to fasten the tab onto the clip,or (ii) the one or more fasteners through the clip to fasten the cliponto the tab.
 16. The method of claim 10, further comprising: using amovable tool to form a plurality of holes in-situ on the plurality ofclips on the solar modules or one or more tabs on the posts.
 17. Themethod of claim 16, further comprising: using the movable tool oranother tool to install the one or more fasteners through the pluralityof holes formed in-situ on the plurality of clips or the one or moretabs.
 18. The method of claim 13, further comprising adding one or morefasteners to the post-clip interfaces during or after the dimplingprocess.
 19. The method of claim 10, further comprising: assessing astructural integrity of the plurality of post-clip interfaces based atleast in part on (i) a measured force or a deflection during or afterinstallation of the solar modules onto the posts or (ii) one or more ofimages of the plurality of post-clip interfaces during or after theplurality of post-clip interfaces have been formed.
 20. The method ofclaim 1, further comprising: using a testing tool located on the one ormore mobile platforms to perform pull strength and assembly tests on theat least one post assembled in (b).